Posted: December 22 2010 at 02:39 | IP Logged

Here are pics of the transom extension and the engine cover. The transom extension is made out of 3/8 aluminum plate beveled and welded on all sides. The top of the extension is made of 1/2 plate and is notched to accept the engine mount. The bottom of the extension has a 3/8 plate with a large oval opening to access the mounting bolts. All angles of the original transom were maintained. I made a mock up of the cover out of 1/4" ply and then constructed a negative (female) mold out of hardened Masonite backed with 3/4" ply. All fillets were rounded with bondo and hand sanded. The large rounds for the mold were made from 4" PVC pipe which were cut to fit the conture and then feathered in with bondo. Extreme caution has to be taken in fitting because the boat sides do not line up and you have to build a slight twist into the mold. I strongly suggest building both sides of the finished piece up to at least 3/8" thick and then sand down for the best fit (provided you have maintained a tight fit to start with). Unfortunately the mold was destroyed in making the piece and I am too scared to risk messing this one up to try pulling a casting from it. I simply have too much work in it.

Send me your email address and I will keep you up dated as I make further mods. my address is bigangel@bellsouth.net

jim

hope this helps