Cowling Separation (Pin Removal)

[BayouBengal]

I’d posted this on my project thread but thought I’d repost here since this section draws the most eyes. I’m restoring a 56 Johnson Javelin and would like to separate the two cowling halves which would make restoration (sanding, painting, etc.) easier.

The two halves are held together by a pin. Bob W suggested that the pin knurled on one end and must be punched out. I’ve beat on with a punch some but haven’t moved it. Does anyone know of any tricks to more easily remove the pin and separate the cowling halves?

[fleetwin]

Great topic….I have often wondered about this as well…

[Bob Wight]

Jeff – did you try heating it up with a torch first?

Bob

1937 Champion D2C Deluxe Lite Twin
1954 Johnson CD-11
1955 Johnson QD-16
1957 Evinrude Fastwin 18
1957 Evinrude 3022
1958 Johnson QD-19
1958 Johnson FD-12
1959 Johnson QD-20

“Every 20 minute job is only a broken bolt away from a 3-day project.”
"Every time you remove a broken or seized bolt an angel gets his wings."

[BayouBengal]

I did heat it. I guess I just have a reluctance to bang on it too hard with it just laying on the workbench with a couple of towels underneath it. I need to figure out a better way of supporting it before I bang on it harder.

[Mumbles]

One end of the aluminum pin is knurled and if you drive it much with a punch and it doesn’t move, that end can expand, locking it in even tighter. Then a Dremel tool with a cutoff blade or something similar must be used to slice it two places so the hood halves can be separated. Getting the remnants of the pin out will be much easier now and a new pin can be made out of a piece of aluminum rod. I’m pretty sure it’s 3/16″ and it can be obtained from a hobby store or a welding shop. A bit of epoxy can be used to hold the new one in place if you aren’t setup to knurl it.

[dave-bernard]

Or prick punch it to flare the ends to hold it in.

[Mumbles]

dave-bernard wrote:

Or prick punch it to flare the ends to hold it in.

That idea would work to.

I’ve done that to pins while making replacement thumb screws by drilling out the end a bit and then expanding it with an appropriate punch.

[BayouBengal]

Thanks guys. Looking at it earlier I was also kind of thinking of cutting it. Of course, it doesn’t absolutely need to be split to restore it, it would just be easier if it were.

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