Looking for tips on a 525 project

[RockyS18]

I posted a thread a couple days ago and I wasn't thinking and deleted it when editing...

Anyway, in my quest for more power I've decided on a 525/XR package. I spoke to Carl C about it a while ago and read his build thread (thanks for your help!). My cousin's Cig is also in need of an engine, so we both saved some money by just dealing between us and he'll be getting my 496. I pulled my engine last week and got an opportunity to clean out my bilge (it looks great nice n shiny!).

If anyone has some advice for the project, I'd really appreciate it.

Sorry for the blurry pic I didn't realize it was blurry until now.

[Carl C]

Beware of the steering police!

[gcarter]

Carl, I think it's the steering brigade!

[roadtrip se]

But I'll give you a few pointers:

1) Beef up the pan with a coring layer. There is inherent flex in the tub and it is going to flex, then stress crack about half way down the bilge on the port side and around the stringers. The transom should be fine, but I would core to and cap the stringers. If interested, PM me, and I can provide you with the lay up I used.

2) Plan on solid, offshore mounts at the least. I have a modified engine cradle hard mounted to stringer mounts. The engine isn't going anywhere. Even with solid mounts, plan on tightening fairly regularly. Again PM me and I can provide pics.

3) Plan on a good twin ram hydraulic system to the helm. I can't tell from your pics, but if you have one, use this opportunity to put backing plates on the transom side for more strength on the transom. These boats will not need more glass work on the transom, but backing plates expand the load bearing surface.

4) I would look at replacing the transom assembly with an HD version. Get the one with the mechanical pivot and digital sender. Easier to do with engine out and a major safety factor. This is also a good time to check the alignment of the assembly, as Donzi got sloppy here on some 496 boats.

5) Carl can talk to you about trials with the differences on gauge senders and such when moving from the 496 to the 525. I didn't deal with this as I am still utilizing a set of 500EFI accessories and senders.

6) Think XR shaft IMCo shorty. Good for 3 to 5 and makes this platform so much more interesting to drive. The X dim is way too low on these boats and you won't be able to maximize the use if your new power with a stock leg. Plan on plenty of prop testing depending on the various conditions where you run your boat.

7) Replace crappy Springfield pot metal seat systems with Garelick Ezzee Sliders. The junk is going to break under the harder load, sooner than later. And at the worst time. The Garelicks are solid aluminum, and superior in every way.

8) Look at your wiring. Now is the time, while everything is apart, to heat wrap all open connections, check the support for the loom and install aircraft clamps every six inches or so. Also take a look at hanging wires in the bilge, and get them out of the way in the same fashion.

9) Take a look at a Hardin sea strainer with Y-valve to keep the water running to your new blue motor clean. Also makes it easier to run on the hose. Also, while you are shopping Hardin, take a look at their stainless water pump. It uses the same impeller, but with a superior body to the Mercury plastic junk.

10) Get rid of the exhaust cans on the transom. Also, chuck the Q&Q or plan on some significant tail work to get it to function. Remember, the 525 has reversion issues, so I would be sure to use very inch of real estate at the transom to get water out of that engine.

11) If you have Bennett's and use them, I would look at kplanes or an equivalent like Dana or Eddie Marine. The Bennett's are just too slow at 80+. Again, easier to do with the engine out. And use backing plates similar to the steering rams on the inside of the transom.

12) Look at the Livorsi or Uflex throttle unit. Still a single lever, but a much easier piece to work with. You are going to want this when funneling that power. Again at 80+, you will appreciate the reaction time to keep from blowing a drive. Some here also have had luck with the Dana controls. I don't like the stick systems, because they require a clumsy pod and poor positioning to make work with our boats.

This is a start. It can be done incrementally, but plan on doing it all eventually.

[Carl C]

http://www.donzi.net/forums/showthre...-W-525-Install

I just re-read my repower thread. It starts out with pages of people telling me that I can't do this myself. Then when I said that I cruise at 70 mph, conditions permitting, more pages of criticism came. Most of that was deleted by Madpoodle. Then the steering police would just not give it up. That was cleaned up also. Twice I was ready to walk away from my thread. Twice it was cleaned up by Madpoodle. My results were fantastic. The boat has run great for 3 seasons now with no problems. Full Zeiger steering is on the boat now. Some people have wondered why there aren't more project threads. I know mine scared a few people away. I will offer Rocky help only through PMs or phone calls.

[Ghost]

(This is rhetorical.) If all the advice about external hydraulic steering was garbage, why spend the money?

I'm reminded of one of my favorite Steven Wright jokes. "I intend to live forever. So far, so good."

[roadtrip se]

Posted by Roadtrip SE on 4/15/2009...

"Let's just say somebody decided...
to hit the delete key on all of his posts, not realizing that somebody else might just have the un-delete key....The joys of insomnia....

I do think some of the posts were a little rough, some of which have been deleted, but you ask for advice on a public forum, and you will receive advice on a public forum. Some of it may not be what you like to hear.

I know, I have enjoyed it on occassion as much as the next guy, even when I didn't think I deserved the abuse. Part of the joy of a public chat board. A thick skin is a requirement...."

Your post above just looks like sour grapes at this point...

[Ghost]

Rocky, apologies if I missed this, but with your serendipitous game of pass-the-motor, will you be keeping your gimbal or buying new? If you're buying new, I'd definitely go with the HD. I don't really know whether the beefier gimbal is needed with the 525, but external steering has got to be the best thing in the world for a non-HD gimbal with a 525.

I totally dig your project, and I suppose you'll likely be the only 009 with a blue motor...

[undertaker]

Rocky your boat is gonna be a sweet set up with the new motor and upgrades, I wanna do the same thing to my boat some day (when I get my big boy pants )...I will be watching this thread very closely and hope to run with ya up at LG this summer....

As a side note I would listen to Todd very closely the guy knows his stuff, also contact Dr Dan, Bob Haver, Dwight Air22 they aren't rookies either...if you need any of there contact numbers shoot me a pm....


Man you are making it tough to not do this to my boat sooner rather than later...


Undertaker

[RockyS18]

Ok, I don'y have a lot of time right now so this is going to be a rather short reply for all the information provided.

First of all, thanks to everyone who has provided advice so far. I absolutely do not want to open a can of worms in this thread, so please let's all put our differences of opinion aside and just peacefully discuss the subject.

My boat is already equipped with Zeiger full hydraulic steering and it has a high x dimension.

I'll post in-depth later.

[Pismo]

Make 110% sure your transom and/or stringers are not wet or rotting. Lots are. Fix it while you have it all apart. Lots easier to do it now if need be.

[DON N.]

Stop up to bolton and talk to jason @ performance marine.
Remember we chatted @ the boathouse.

[Pat McPherson]

If there is any question about the stringers, add reinforcement.
A "race" engine mount is a no brainer as it will tie the sringers together. You don't want the engine to move around at all.
K-planes are better than Bennetts but if you have the double pistons, I wouldn't bother.
No captain's call with a 525; use mufflers if you must.

[Pismo]

Carl I believe has switchable exhaust on his setup. Take a look.

[Carl C]

"Carl I believe has switchable exhaust on his setup. Take a look."

Yes. It requires special divertors and is only usable up to 2,500 rpm according to the Mercury 525 service manual. I only use mine off plane. I already told Rocky that one of his biggest expenses will be fitting the exhaust whether he goes with Q&Q or not. I also agree that the hull needs to be reinforced while the engine is out. If it were me I would do something like the factory reinforcement kit with a couple extra layers of stitchmat. It can be done in a couple of weeks.