FINALLY found an 84' 255 AJ to buy!

Well, the engine is all sealed up now. I'm going to finish with all of the accessories and external parts tomorrow. Here's a pic of the engine as I left it today. I wish I'd had more time...
ba9a16e3.jpg


I have to find a source on the gaskets for the remote filter adapter, it's a Merc. part number, but my local West Marine didn't have it...as a matter of fact, talking to them was like walking into my local Autozone. Nobody had a clue, and when I said 1984, they really acted like this was some antiquated relic. ugh!

So who carries these gaskets? I can just put the oil filter on the block in the meantime if needed. There's easy access to it in the AJ anyway.
This is the adapter that attaches to the block, I'm considering silicone since it is rarely removed, but it had a rubber gasket and I DO NOT want leaks.
3cd6573e.jpg


This is the bottom portion of the adapter.
adcc3830.jpg


Oh, and I picked up a thermostat kit today, the gaskets match, but I'm trying to figure out how to remove the thermostat itself, time to dig out the Mercruiser manuals.
f3425738.jpg
 
Oh, and I also ordered a Lowrance HDS7 today, should have it Monday...and a new VHF antenna...and a new VHF since the current one does not have DSC. I think I'll be installing the electronics once I have the boat water tested a day or three.
 
Where did you get your Quadrajet rebuild kit from? I'm considering rebuilding mine while I go through my motor. I'm curious to see how your rebuild turns out.
 
MMcCawley said:
Where did you get your Quadrajet rebuild kit from? I'm considering rebuilding mine while I go through my motor. I'm curious to see how your rebuild turns out.
Click to expand...
How familiar are you with the Rochester carburetor? If you are not 100% sure about your experience level with them, I would highly recommend Carb Junkies. They will ask you some very specific questions about your setup, when you get it back, all you should have to do is bolt it on and set the idle. Those guys are really good.

I bought the kit through Summit Racing.
 
You are making some big progress!

Looking forward to the pics of smiles on launch day
 
Well I got a bit of bad news, the interior shop won't have the boat done until late next week...it was supposed to be today! So I told them to just do the whole interior rather than trying to just get the rear bench done ASAP. With us leaving to go out of town in a few weeks it looks like we won't be in the water until late June...now I guess the goal is to have it ready for the 4th of July.

On an optimistic note, I'm sure it will eventually be worth it. :grin:
 
I finished the carb up today, it was actually very clean inside. I'm thinking that someone spent a lot of money on this boat intending to use it and then for whatever reason sold it after it sat for a year or two. The gaskets were in really bad shape, very dry, and one of the idle screws was about 50% richer than the other. I suspect that there was a vacuum leak that made them have to richen it up to run right. I installed some hoses, the carb is just sitting on it, fuel pump and manifolds are on as well. I had to go to West Marine again, this time my experience was MUCH better, they were able to find 2 of the molded hoses I needed and ordered 2 more for me as well.
Today's parting shot.
0844fd06.jpg


I got the same style coupler, the newer style is about double the cost, I do like the newer one, but I put 1,000 hours on an old style coupler years ago without issue so I'm sure it'll be good.

The thermostat housing I was asking about yesterday, there is a brass retainer inside that holds the thermostat in place inside the housing, it simply taps out and taps back in...simple.
 
270win said:
How familiar are you with the Rochester carburetor? If you are not 100% sure about your experience level with them, I would highly recommend Carb Junkies. They will ask you some very specific questions about your setup, when you get it back, all you should have to do is bolt it on and set the idle. Those guys are really good.

I bought the kit through Summit Racing.
Click to expand...

This may help you out: a word doc I put together and posted on my website. It was compiled from browsing the internet before rebuilding ours, with pictures, instructions and what to look for when rebuilding a quadrajet:
(the link should just download the document for you - hopefully with the pictures)

http://www.midwestconnection.com/images/misc/boat/forum/quadrajet rebuild.doc
 
Last edited:
Good link and great source of information.
 
270win said:
I would highly recommend Carb Junkies. They will ask you some very specific questions about your setup, when you get it back, all you should have to do is bolt it on and set the idle. Those guys are really good.

I bought the kit through Summit Racing.
Click to expand...

Thanks, I'll check them out!

Did you do anything to your motor or is it all stock?
 
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KC_Sundancer said:
This may help you out: a word doc I put together and posted on my website. It was compiled from browsing the internet before rebuilding ours, with pictures, instructions and what to look for when rebuilding a quadrajet:
(the link should just download the document for you - hopefully with the pictures)

http://www.midwestconnection.com/images/misc/boat/forum/quadrajet rebuild.doc
Click to expand...

Wow, great resource, thanks. Not sure if I'm going to tackle it myself yet but if so your manual will come in handy. Thanks again.
 
Interior shop called today, they're 1/2 way done now, said they'd be finished with it mid-next week. The engine is completely done, the outdrive is ready to go, I have all the parts to put her back together, just gotta clean her up and install everything.

Oh, but I do still want to look at my gimble bearing just to be sure, I'm not anticipating any issues though.

Of course I'll post interior pics once I get her back.
 
I went to take a look at the boat today and I'm glad I did! Here's a pic of the back bench.
13e77d02.jpg


It looks great and the box underneath is perfect, they used the dimensions I agreed to, but it's no where near deep enough. We're adding 8" of depth to the seat bottom. As it is, when I sit there, the front edge of the seat cushion is 1/2 up my thigh, feel like I'm going to fall into the floor, and sitting sideways is not possible. They said no sweat, still should be done next Friday and I'm going to fabricate some legs to support the front edge of the seat bottom.

Seeing the boat re-lit my boat fever!!!
 
270win said:
I went to take a look at the boat today and I'm glad I did! Here's a pic of the back bench.
13e77d02.jpg


It looks great and the box underneath is perfect, they used the dimensions I agreed to, but it's no where near deep enough. We're adding 8" of depth to the seat bottom. As it is, when I sit there, the front edge of the seat cushion is 1/2 up my thigh, feel like I'm going to fall into the floor, and sitting sideways is not possible. They said no sweat, still should be done next Friday and I'm going to fabricate some legs to support the front edge of the seat bottom.

Seeing the boat re-lit my boat fever!!!
Click to expand...

I agree. My seat is almost 30" deep.




Sent from my iPad using Tapatalk HD
 
Does that stay in place when you access the engine room?

Nice upholstery work!
 
I launch my boat tomorrow... I am not doing an 8th of the work you are and for some reason I am not seeing any pics in any of this thread excpet the pics in the signatures...

But man it took me about 25 min to read through this whole thread and I am ready to start working on my boat!! I don't have the single that you guys do but the 2 185 mercs. this is my first boat and you guys seem to know boats like you were born on them. I just wanted to say how much i appreciated this thread. Although it's a different year I am sure it is close enough to being like mine that i will come back to this over and over to get ideas...
 
Getaway said:
Does that stay in place when you access the engine room?

Nice upholstery work!
Click to expand...
Thanks! Yes, it does stay in for basic maintenance items, but for engine r&r it comes out. It also makes a nice storage box under the seat. I'm going to make a star board cover to take the bench's place for fishing trips.
 
DouglasMB said:
I launch my boat tomorrow... I am not doing an 8th of the work you are and for some reason I am not seeing any pics in any of this thread excpet the pics in the signatures...

But man it took me about 25 min to read through this whole thread and I am ready to start working on my boat!! I don't have the single that you guys do but the 2 185 mercs. this is my first boat and you guys seem to know boats like you were born on them. I just wanted to say how much i appreciated this thread. Although it's a different year I am sure it is close enough to being like mine that i will come back to this over and over to get ideas...
Click to expand...
I'm not sure why all the pics aren't coming up...feel free to ask any questions here or on the Classic Sea Ray board. There are some extremely knowledgeable folks on this site. Hope your launch goes well!
 
270win said:
Does your bench have feet for support or is it built on a big box?
Click to expand...

It is built on a frame. It's getting pretty rickety but still holds up well once the seat bases are on it. The bases are very heavy. I have two main bases the middle is made up of a 12" wide divided that fits into the frame that hold some cup holders and a insert to convert it into a bench. You might be able to see what I am talking about from the pics in my profile.


Sent from my iPad using Tapatalk HD
 
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