My scag broke off 1 inch from the base of the casing. I was told if I weld a new scag on so close to the casing, the heat will damage the gear oil and gears that operate the prop movement. Is this true and if so is removing the bottom casing my only option for repair work?
No!!!!!! Welding your skeg is the best option. In fact this is done all the time. The gear case needs to have the gears, shafts, and even the oil in the case, which help to dissipate the heat and prevent the housing from warping. The remaining part is usually ground down to an inch or so, anyway. If you notice the "web" thickens as you get near the "bullet". I've never had any problems with gears or shift operation after this was done. Over the years I've had hundreds of skegs welded, but I depended on the professionalism of the shops. Most of the shops I used also repaired props, so they understood Alum welding and marine issues. If they didn't feel it could be done they would tell me. I depended on their advise. Early on they fabricated the "new" skeg them selves. Now, they are readily available. It's a matter of grinding the old (broken) skeg off and welding on the new blank. I've had this done in Maryland and Florida, and a "distributor" who would pick up the case, take it to N.J. to a shop they used, and then bring it back the next week. So, contact someone in your area and ask where they have had this work done in the past.
It's over $1500 cheaper than replacing the lower case.
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