Cutless bearing Stern Tube Fun

[ArtJ]

I removed the cutless bearing in My Tartan34 direct drive engine yesterday

The shaft coupler came of in excellent condition after pb blaster and vise grips
to 3 bolts. The plan is to reuse coupler and 1" bronze shaft as both are in very good condition.

The shaft log came off readily after removing the 2 clamps
The plan is to replace hose and clamps and reuse stuffing
The shaft with Indigo prop pulled out at the stern there was almost unnoticable
wear at cutlass.

The Cutlass took a couple of hours to persuade out.
Made 2 very careful cuts with fine metal blade on sawzall
Banged with round drift inside set screw holes , pry on halves
of cutless outward until cutless became loose then pushed out with rod from inside

cutless measures ID 1 inch OD 1.5 inch Length 4 Inches

I found a Johnson DUR-870252105 with same dimensions
at Hamilton Marine for $79.99

Need a source to replace the 3 bolts to the reusable shaft coupler what material ?

Also a source for two allen set screws holding Cutless

Plan to replace hose and clamps on Shaft log and reuse

Reinstall of Cutlass:

Was thinking of using CRC Freeze Mist to shrink Cutlass for
installation?
Was thinking of using block of wood and 2lb hammer to drive it in?

Articles suggest using soap to lube tube for insertion Dawn ok?

Also mentions having 1 single grove facing down in cutlass bearing ??

Alternative is 1/2 inch 2 ft plus length threaded rod (poor access) with
large thick washers??

Comments suggestions appreciated

Thanks

Art

[Al Schober]

What made the old cutless hard to remove was corrosion. New cutless has no corrosion. Clean up the ID of the stern tube and it should just slide in.
As for the set screws, source of last resort is McMaster. My local hardware probably has them (HD might be able to order them, but when they finally come in they won't be able to find them).

[ArtJ]

Thanks Al

I have all parts arriving today to reassemble the cutless drive shaft et al tomorrow.

I have got a 1/2 inch 3 ft threaded rod with large heavy washers to use as puller if needed. Will start with rubber mallet or 2 lb hammer with block of wood.
New Algonquin Hose for stuffing/ shaft log with new clamps.

New grade 8 bolts for shaft coupler

the old cutless set screws matched up with new 5/16 inch dimpled allen set screw ones

The threads in the allen hole still look good

My concern is that I hope the mouth of the stern tube has not been made out
of round slightly by my "helper" aggressively using chisel to separate pieces of cutlass .will find out tomorrow if so, maybe a tapered 1" wooden dowel could
round it or slightly file it at protruding mouth ?
Again not sure that out of roundness is a problem, Doing it again
I would have ensured that the cuts were completely thru the entire length
before prying. Of course cutting is a delicate operation

. Getting it started back in is the biggest
part of the struggle I assume.
Are the cutless bearings some times epoxed in the tube? I do not plan on that.Is expoxying the set screws in sufficient or should loctite be used as well?

I have some electronic ckt cooler to frost the cutlass metal exterior only (not the rubber part) and will put some dishwashing liquid into the mouth of the tube to lube
temporarily. I plan to install tomorrow Wednesday
Will check back for any last minute advice later today.

Thanks Art

[ArtJ]

Cutless, stuffing box and shaft coupler reassembly went together very smoothly without
need for puller or heavy hammer. 1/4 inch play is eliminated. The effort
was in the removal, especially the cutless.

Thanks to all

Art