TOPIC: Merc 800 FGS restoration

Hey All,

I have started restoring a 1961 Merc 800EL-1.


Never had it running but it cranks about 110 psi across all six cylinders. So I am hoping rebuilding the ignition, electrical, fuel system, and lower unit will make it go again.


The drive shaft shows wear at the water pump seal location and intend to send it out for flame spraying before reassembling.

Dr Frankenmerc,

Curious how you get the motors you restore to look so pretty.


It appears that the powerheads are painted and would be interested to know what you use. This 800 looks rough and I do not know if simply cleaning it will be sufficient.

Also would like to know what you use for the Cloud White paint. The last one I restored I had a friend spray it with Imron and do not want to take that route again.


In the process of blasting the parts now and I will be painting this one myself.

Thanks,
Terry

I have my painter use 1992 VW Cashmere white.
PPG paint, "base - clear"
I have him use a base - clear 'bright silver' on the engine block.
I can get both paint codes if needed.
I polish the stainless, and aluminum parts with a cheap Harbor Freight buffing & polishing bench mounted devise.
It is visible in the picture of my beast that you added to your post.
I plan on spending a bit more money on a larger buffing-polishing set up.

I have attached a print-out of the different polishing rouges.
doc

Thanks Doc,

Looking for a few parts.

Anyone know of a source for the shocks?

Also need the rubber shock bushings.

upper and lower rubber mounts

And this trim cover got mashed.

Thanks,
Terry

Terry,
It appears that www.marineengine.com actually has NOS upper & lower rubber mounts.
They also have the rubber bushings for the shock absorbers, but not the shock absorbers.
Your shock absorbers look pretty decent. If they work okay, and don't have any dents, etc - why not use them??
I might have some decent used ones if needed.
Believe it or not,...They actually indicate that they also have the NLA/NOS trim cover.
Yours could probably be straightened with an English Wheel. A pal of mine has rescued several of those for me with an English Wheel.
They also have the inside & outside covers & related rubber washers for the upper mounts.
All this is pretty amazing IMHO, but they haven't failed me yet.
doc F

Cool Terry I have the same motor but haven't started on it yet. Mine has 90 across all cylinders and was sitting outside so I'm hoping that's just stuck rings. Thanks for asking the colors I need this also.

Thanks Doc good stuff, good to know the rough colors also. i have the same buffer, haven't christened it yet. Bought it to buff up the chrome and stainless on the Century Resorter.

Bob

Hi Terry, in case the dated e-mail address I used to write to you on Tuesday noon is no longer good, I would be happy to resend the information if you would let me know.

Best,
Joe
This email address is being protected from spambots. You need JavaScript enabled to view it.
www.fergusonpoolemarine.com

Terry,

Looking forward to your progress. I use PPG & BASF. I also use www.reprotint.com/ . All depends on what quality your looking for, of course the first 2 are top notch and will get you a concourse quality finish. Reprotint sells rattle cans also. I have a few paint codes attached.

Travis

Thanks for everybody's input.

Good to know the rubber parts are still available through Marine Engine and Joe Poole says he has them in stock too. Joe also said he has a housing cover replacement and aluminum replacement shocks.

I want to keep this restoration as original as possible so will need to find used shocks if NOS are extinct. What I have pictured above leaked and are shot.

Still blasting parts today but need to make a decision on paint soon.


This is the Merc 800 I have on Mama Mia! now after a fresh coating of Imron.

Terry

JMHO,...But I would encourage you to purchase a small sample of '92 VW "Cashmere White",...PPG # 3398, and compare it to a small sample of Ford's "Wimbledon White", PPG # 8378.
doc

Thanks Doc,

When I did the last Merc I had the supplier custom match the Imron to what was inside the control. And it appears to be a good match to what was on this motor.

IYHO how consistent was the Mercury Cloud White in production.


Eastwood Wimbeldon White Basecoat

Thanks,
Terry