We will try to have an article each month on this page concerning maintenance, performance, and overhaul procedures. Also, we will try to post the names and addresses of businesses making parts, or providing services for V Drives.
Please be aware that the information on this page may not work for everybody. In some applications, it could even be hazardous. It is up to you to use your own good judgment, and determine what is right for you.
How often have you run across the situation where
a part you need just doesn't exist. You look high and low, but it seems
that no one makes it. Well, with a little imagination, and a lot of patience
and sweat, you can make just about everything you need. That's the basis
for this article. We'll look at some of the tools and equipment needed
for making certain items, and what to look for in tools and equipment.
As an example, I needed a new drive mount for
my drive. The original Casale v-drive had been removed from my Howard by
one of the previous owners, and replaced with a Crusader. The mounts on
the Crusader were more of a day cruiser mount, and had been modified by
the previous owner to fit the hull. The previous owner had not given enough
consideration to what they were doing when installing the mounts, and the
whole thing was quite dangerous the way they had it installed.
I decided to make a new mount, one that was much
stronger, to fit the Crusader drive I had. After some brainstorming with
my partner in crime, Bart, we decided to make a mount out of 3/8" T6 Aluminum.
At first, I had thought of cutting several pieces and welding them together,
but as Bart pointed out, Aluminum gets soft in the welded areas, and might
not be as structurally tough as the rest of the pieces. We therefore decided
on bending some of the aluminum, and bolting other parts together.
For the front of the mount, we used 4"x4" T6 angle aluminum, 3/8" thick,
with plates of 3/8" T6 plate bolted together to attach the inside and outside
pieces together. The rest of the mount was made with 3/8" T6 plate aluminum,
that was bent to give the proper fit. To cut the angle aluminum, we used
both a band saw, and a reciprocating saw. 
The
reciprocating saw was used to make the rough cuts, and then put through
the band saw to get the final cut. To make the bends in the plates which
would become the sides and rear portion of the mount, we had to fabricate
a die and mandrel.
Fabricating the die was done by using the rear
axle of a Ford station wagon, and two pieces of 1 1/2" angle iron, 1/4"
thick. the axle was cut into smaller pieces that were welded to the angle
iron. A gap between them, the width of the mandrel plus the 
thickness
of the aluminum plate, was left between them. The mandrel was a wrist pin
from a tug boat engine, and was approximately 1 3/4" in diameter, and 6"
long. With this die and mandrel, we were able to form the curves in a mechanical
press. I have to admit that it took some time and effort to set up everything
and do the actual bending, but the
results were exactly what I wanted.
Once the pieces were bolted together, the drive
was test fitted in the hull. Once I was satisfied that all the pieces would
fit correctly, the mounting holes were drilled through the stringers, and
the drive and mount bolted in. The new mount is much stronger than the
original set up, and far safer. It also lends some structural strengthening
to the hull.
All together, I have about 15 hours of time, and
$85 of materials in the new mount. Its the time factor that will be the
biggest when making your own parts. However, if you enjoy making your own
things, and have the time needed for a project like this, then the rewards
are great.
As for equipment you would need for a project
of this sort, you can spend a little, or a lot. For this project, a band
saw, reciprocating saw, blades for both, a MIG welder, 4" angle grinder,
and press were needed. You don't have to buy new equipment, as there is
plenty of good used equipment available. The main thing is that when your
buying used equipment, check it out thoroughly. Also, if given the choice
between something 10 years old, and 40 years old, the newer might not be
better, considering price. While an old mechanical press may take a lot
of effort to use, it could save you in the long run. Power equipment needs
to be checked for signs of abuse. Cords that cut and spliced in several
places may look bad, but if the rest of the power tool looks good, a new
cord might be worth it.
There are a few pieces of equipment that you should
buy if you plan on buying an older boat, or want to do some serious work
on a present one. A good reciprocating saw with variable speed is a good
investment. It makes cutting aluminum a less time consuming chore. A drill
press is another good piece of equipment to buy for drilling accurate holes.
A 4 inch, or 7 inch angle grinder comes in handy when welding becomes necessary.
A MIG welder is also a good investment, but make sure you get one that
will weld both steel and aluminum. Another good piece of equipment to have
around if you have an older boat, is a small bench lathe. A small bench
lathe can be used to make hundreds of small parts that can't be bought.
Another tool that is indispensable, is your PC.
There are a few good CAD programs that are designed for the average person
to use. They might be a bit frustrating to learn at first, but once you
get the hang of it, they become quite useful. With a CAD program, you can
layout your designs, and change them down the road if you get a better
idea.
We hope this article will give you some help when
you find you can't buy what you need, and feel you could build what you
need if only you had the tools. It doesn't take a lot of money, just a
lot of labor, which for most of us is a labor of love for our boats. Also
remember that you already have one of the best tools available. Your brain
and imagination.
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