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- First, you must remove the propeller. To do this, start out by bending the cotter pin and remove it using side cutters, then remove the keeper.
- Block the propeller with a piece of wood (figure A), and then remove the propeller nut with a ratchet. Take out the piece of wood, and remove the propeller (figure B).
- Draw out a large zigzag pattern about 1" from the part closest to the gear case (figure C). Using a reciprocating saw with a fine tooth blade, cut off the skeg below the pattern. Then take a jig saw to cut out the zigzag pattern.
Safety Tip:Always use safety glasses when cutting metal and wear gloves to protect your hands.
- Take the new skeg; place it behind the skeg that remains, clamping it into place. Be sure that the top and bottom edges are aligned (figure D). Draw out the zigzag pattern, then cut out the pattern using a ban saw. The metal will heat up after cutting, just dip it in cool water and continue.
- Next, you will need to grind a 45-degree V-notch (figure E) -- using 60 grit sandpaper -- on both sides of the zigzag cut to give the weld more surface area to hold together.
- It's time to start welding. You may need to hire a welder to do this part, which could cost around $25. Most welders use a mig welder with an aluminum rod to set the piece in place. If you hire a welder, make sure they fill up the gear case with water, so that the heat from the heat from the weld doesn't cause any damage. They should also apply a wet rag in between the welding of the tiers.
- After the welded piece has cooled, you can grind down the weld (figure F) to give a smooth finish using an angle grinder with a 60 flap disk.
- Apply marine grade body filler, a two-part solution where you have a base and a solution. Mix them together, and then apply with a plastic applicator, wiping it in two directions to ensure that the seam is blended. Once the filler has cured, sand everything down with 180 grit sandpaper. Clean area with denatured alcohol.
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