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My buddy's boat after today's wakeboarding trip.  Hit some submerged wood (found wood fibers in the speedo hole and in the screw recesses above the prop).  Lower unit casting got a large chunk taken out of it and big crack behind that.  SS prop got damage on all three blades.While I'm sure I could probably TIG the prop, I'm not so sure about getting all the surfaces back where they need to be afterwards.  Thinking this might be best left to the pros.  If you could PM me a ballpark, I can pass it on to my buddy.The lower unit casting I'm feeling a little bit better about.  The casting that got damaged unbolts just above the damaged area.  Thinking the repair would go something like this: recreate the missing piece (looks like it thins towards the edge), remove casting and pull everything out of it, mask off openings, sandblast area in vicinity of repairs, bevel edges to be welded, weld, smooth down beads, repaint or powdercoat (which would probably call for some additional degreasing, sandblasting, and outgassing).  Anything I'm missing or other tips?  Recommended filler for these types of castings? Attached Images
Reply:It's a '94 MerCruiser Alpha One, Gen 2 stern drive if that helps.
Reply:Ahh the joys of owning a B.O.A.T....   Break Out Another Thousand.I'd think the prop could be fixed pretty easily but not sure on the lower unit as I have no idea what kinda material it is made out of.  Some sort of cast aluminum alloy would be my guess. Interested to see the fix for it thoug.
Reply:awwwww  easy repair ---no step for a stepperprop has been repaired b4... still easythe cavitation plate is repairable, dropping the lower unit would be recomendedplacing a thick plate (steel) on cav. plate to help reduce warping, clean groove and weldflip over and same process again -- paint with gloss black..($70 The prop-- put on pitch block to check and straighten, weld, grind,and balance (my fee $90 with a satan finish -- if wanted polished to mirror add 45 i would replace the zinc anoid with a new oneidealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:Originally Posted by prop-doctorawwwww  easy repair ---no step for a stepperprop has been repaired b4... still easythe cavitation plate is repairable, dropping the lower unit would be recomendedplacing a thick plate (steel) on cav. plate to help reduce warping, clean groove and weldflip over and same process again -- paint with gloss black..($70 The prop-- put on pitch block to check and straighten, weld, grind,and balance (my fee $90 with a satan finish -- if wanted polished to mirror add 45 i would replace the zinc anoid with a new one