240 BR Rebuild

Ytmsn
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Re: 240 BR Rebuild

Post by Ytmsn » Tue Sep 27, 2016 9:35 pm

The freeze crack is more like a freeze explosion.
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240 BR

Ytmsn
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Re: 240 BR Rebuild

Post by Ytmsn » Tue Sep 27, 2016 9:36 pm

And now the block is in engine... purgatory!
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240 BR

Ytmsn
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Re: 240 BR Rebuild

Post by Ytmsn » Tue Oct 11, 2016 7:08 am

I pulled these little puppies out and it wasn't fun! And then after searching the Web over and over for a way to redo or refinish them I discovered Tecnographics in Florida. They have the contract to do all the dash panels for Cobalt, so I ordered OEM replacements.

Not cheap...but I also learned that by doing it mysef, it would have taken a very long time, and this time of year that's something I don't have a lot of. Also, the intrument panel is fine, and I was worried about getting an exact match.

Then the lettering was an issue. I looked into several different methods of silkscreen, or something similar. . This problem could have been worked through, no doubt, but in the end I justified the extremely high price for the convenience of placing an order and getting the exact panels I need.
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240 BR

Big Block Power
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Re: 240 BR Rebuild

Post by Big Block Power » Tue Oct 11, 2016 12:42 pm

Those are pretty rough. When I look at buying a boat those are the panels I look at to tell if the boat sat out in the sun. Good way to tell. Glad you found replacements. That's good to know. John you may want to bookmark that company some how?
2003 Cobalt 220 8.1gxi
Neenah Wi

jhnmdahl
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Re: 240 BR Rebuild

Post by jhnmdahl » Tue Oct 11, 2016 1:19 pm

I made a new parts for sale/trade/free subforum and moved the posts trying to sell things there, and created a new post in the now cleaned-up parts forum mentioning this. Might be worth making a sticky with a list of manufacturers at some point too.
Administrator of the www.cobaltchat.com Cobalt boats community forum

Ytmsn
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Re: 240 BR Rebuild

Post by Ytmsn » Fri Oct 28, 2016 11:37 am

I finally got my panels back in the mail. They look great! Now I'm probably going to pull my dash and do the same thing so they'll be an exact match, but that might be next winters project.
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I also picked up my interior. I'm doing things just a bit different to get a little pop out of the appearance and I'm hoping when it all comes together it'll look right. I had red piping added to the seats and a few other strategic places.
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240 BR

Ytmsn
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Re: 240 BR Rebuild

Post by Ytmsn » Fri Oct 28, 2016 11:52 am

My original steering wheel is toast, and a replacement from Cobalt is ridiculously expensive, so I ordered one of these from Lacarra. After the red boot stripe is added it should all tie in (fingers crossed)
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Then I took Big Blocks lead and bought this on Ebay. One of the last things to address will be the stereo system, speakers and LED lighting.
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240 BR

Ytmsn
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Re: 240 BR Rebuild

Post by Ytmsn » Fri Oct 28, 2016 11:54 am

I don't know why my crazy phone won't turn the pictures right. Sometimes I'd like to throw this thing like a grenade!
240 BR

Big Block Power
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Re: 240 BR Rebuild

Post by Big Block Power » Fri Oct 28, 2016 12:53 pm

I have learned to take all pictures with my phone sideways.No more up Right pictures. For some reason forums don't like them that way.
I like what your doing.nice touches.:-)
2003 Cobalt 220 8.1gxi
Neenah Wi

Ytmsn
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Re: 240 BR Rebuild

Post by Ytmsn » Sun Dec 11, 2016 7:04 am

My motor is done. They bored a replacement block 30 over so I got new pistons and rings. Pulled all the components out of my old block and checked tolerances, and it was all great. Reinstalled the components with new bearings, bushings, seals, etc. All the machine work was done to the heads and everything went back together perfectly. Loaded her up and carried her back to the boat shop.

They got the engine installed, reinstalled the outdrive, and started her up to break in the new cam.

Eeww.

My fuel pump screeched when it first fired, so they pulled the pump assembly off, broke it down and cleaned it out. It was full of goo...

The mechanic cleaned it out and put it all back together. It's running, but the pump has me worried.

I may end up ordering a new pump assembly, or at the least the HP side to carry as a spare. Dang.

I've been reading and researching all of the problems that seem to be inherent with these Volvo pumps. Black paint, the hp side running super hot, yadayada. Anyone else here have any fuel pump issues?

The saga continues...
240 BR

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