When this project started it's scope was to simply replace the old worn cutlass bearing. It has been expanding rapidly. In my heart I knew that the prop shaft had come out way too easily, taking just 15 minutes. So, I was waiting for the other shoe to drop. Well it did and quite quickly. The first thing I found was the prop shaft was worn and had corrosion channels were the stuffing box met the shaft. The shaft was also rubbing on the stuffing box, it looks like I'll have to replace the stuffing box as well.
For the new shaft the machinist wanted me remove the shaft coupler so he could mate the new shaft and coupler for a good fit. Well another surprise! When I removed the coupling there was motor oil in between the couplings and marks on the sides of the engine compartment where oil had been flung. I checked with the Sailnet Atomic 4 group to see if they had any insight on where the oil was coming from. The consensus was a bad rear oil seal.
I called Moyer Marine (the A-4 folks) to order parts and ended up talking to Don Moyer about the problem. He said it sounded like oil was getting past the output shafts key way to the engine coupling. He told me to loosen the nut and see if there was play between the shaft and the coupling.
This is where the story stops until I can get down to the boat to follow Don's recommendations. Check back later to see what's next. There will be pictures coming are well.
Until later,
Stephen Petri