CLASSIC MERCURY SERVICES
WaterHogsWorks specializes in the restoration, rebuilding and preservation of classic Kiekhaefer Mercury outboards.
From complete restorations and precision powerhead machining to carburetor, ignition and component rebuilding, our focus is on preserving these remarkable engines and keeping them running for another generation.
We specialize primarily in the classic Mercury outboards of the 1950s and 1960s, with particular experience in the four-cylinder Mercury family.
POWERHEAD MACHINING
Vintage Mercury two-stroke powerheads require machining practices that differ from conventional automotive engines. Blind-bore cylinders, two-stroke ports, obsolete pistons and rings, unusual clearances and decades-old castings require careful measurement and an understanding of the engine being machined.
WaterHogsWorks provides precision machining specifically for classic Mercury powerheads, with each cylinder machined and finished according to the actual piston and ring combination being used.
Powerhead Inspection & Measurement
Cylinder bore diameter, taper, out-of-round and overall condition are carefully evaluated before machining begins.
Precision Cylinder Boring
Each cylinder is machined based on the actual piston that will be installed rather than simply boring to a nominal dimension.
Finish Honing
Final cylinder sizing and surface preparation are performed according to the piston and ring combination being used.
Port-Edge Finishing
Following machining, cylinder-port edges are carefully inspected and deburred or chamfered where necessary to protect the piston rings.
Final Cleaning & Inspection
Machined powerheads are thoroughly cleaned, remeasured and inspected before being released for assembly.
EVERY MACHINED POWERHEAD IS DOCUMENTED
Whenever applicable, WaterHogsWorks provides a dimensional machining record documenting the condition of the powerhead before machining, piston dimensions, final cylinder dimensions and finished piston-to-cylinder clearances.
This provides the owner with a permanent record of the machine work performed and the specifications used during the rebuild.
Sample Machining Record
Cylinder #1
Initial Bore: ______
Piston Diameter: ______
Final Bore: ______
Finished Clearance: ______
Cylinder #2
Initial Bore: ______
Piston Diameter: ______
Final Bore: ______
Finished Clearance: ______
Cylinder #3
Initial Bore: ______
Piston Diameter: ______
Final Bore: ______
Finished Clearance: ______
Cylinder #4
Initial Bore: ______
Piston Diameter: ______
Final Bore: ______
Finished Clearance: ____
Preserve it. Measure it. Machine it correctly. Document everything.
POWERHEAD REBUILDING
WaterHogsWorks offers complete powerhead inspection, machining and rebuilding for classic Kiekhaefer Mercury outboards.
Each powerhead is carefully disassembled, cleaned and inspected before rebuilding begins. Critical components are measured and evaluated, and any required cylinder machining is performed to match the actual pistons and rings being installed.
A typical powerhead rebuild may include:
Complete Disassembly & Cleaning
Cylinder Inspection & Measurement
Crankshaft & Connecting-Rod Inspection
Piston & Ring Evaluation
Bearing Inspection
Cylinder Boring & Finish Honing When Required
Piston Fitting & Clearance Verification
Port-Edge Finishing
Seal Replacement
Careful Reassembly & Final Inspection
COMPLETE RESTORATIONS
WaterHogsWorks performs complete mechanical and cosmetic restorations of classic Kiekhaefer Mercury outboards.
Each restoration begins with a careful evaluation of the engine and progresses through complete disassembly, inspection, mechanical rebuilding, component restoration, refinishing, reassembly, setup and testing.
Our goal isn’t simply to make an old Mercury look new. Our goal is to preserve the character of the original engine while restoring it to operate the way a Mercury should.
A complete restoration may include:
Complete Disassembly & Inspection
Powerhead Rebuilding
Cylinder Inspection & Machining
Carburetor Rebuilding
Magneto & Ignition Service
Fuel-System Restoration
Cooling-System Service
Lower-Unit Service
Hardware Restoration
Surface Preparation & Refinishing
Period-Correct Decals & Detailing
Final Setup & Testing
CARBURETOR RESTORATION
WaterHogsWorks provides complete carburetor rebuilding and restoration for classic Kiekhaefer Mercury outboards.
Each carburetor is completely disassembled, cleaned and carefully inspected. Fuel passages, jets, floats, needles, seats and throttle components are checked for condition and proper operation before reassembly.
Carburetor service may include:
Complete Disassembly & Inspection
Ultrasonic Cleaning
Fuel-Passage & Jet Cleaning
Float Inspection & Adjustment
Needle & Seat Service
Gasket & Seal Replacement
Throttle-Shaft & Linkage Inspection
Reassembly & Initial Adjustment
Individual carburetors and complete matched sets are welcome.
MAGNETO & IGNITION SERVICES
WaterHogsWorks provides inspection, rebuilding and service of classic Mercury magneto and ignition systems.
Vintage Mercury ignition systems require careful inspection and correct setup. Worn points, deteriorated wiring, weak coils, damaged components and incorrect timing can all affect starting and performance.
Magneto and ignition service may include:
Complete Magneto Inspection
Points Inspection & Replacement
Condenser Inspection & Replacement
Coil Inspection & Testing
Distributor Inspection
Ignition Wiring Inspection
Spark Testing
Timing & Synchronization Setup
Final Operational Inspection
Individual magnetos and ignition components are welcome for evaluation and rebuilding.
FUEL-SYSTEM RESTORATION
WaterHogsWorks provides restoration and rebuilding of the fuel-system components used on classic Kiekhaefer Mercury outboards.
Decades-old fuel lines, fittings, hoses and related components are carefully inspected and restored or replaced as required for dependable operation while maintaining the period-correct appearance of the engine.
Fuel-system services may include:
Fuel-Line Inspection & Replacement
Period-Correct Reproduction Fuel Lines
Fuel-Pump Inspection & Rebuilding
Fuel Fitting Inspection
Hose & Connection Replacement
Leak Inspection & Testing
Fuel-System Cleaning
Final Assembly & Inspection
Reproduction fuel lines are available for selected classic Mercury models and are made to closely duplicate the appearance and routing of the original assemblies.
REPRODUCTION FUEL LINES
WaterHogsWorks produces reproduction fuel lines for selected classic Kiekhaefer Mercury outboards.
Each line is made to closely duplicate the routing, length and appearance of the original Mercury fuel-line assembly while providing dependable operation for an engine that is meant to be run.
Reproduction fuel-line services may include:
Complete Fuel-Line Sets
Individual Replacement Lines
Original-Style Routing & Fitment
Fuel Fittings & Connections
Custom Lines Made From Original Samples
Original fuel lines or fittings can also be supplied as patterns when required.
LOWER-UNIT SERVICE
WaterHogsWorks provides inspection, servicing and rebuilding of classic Mercury lower units.
Decades of use and storage can leave seals hardened, lubricant contaminated and internal components worn or damaged. Each lower unit is carefully inspected and serviced according to its condition and intended use.
Lower-unit service may include:
Complete Disassembly & Inspection
Gear & Bearing Inspection
Driveshaft & Propeller-Shaft Inspection
Seal Replacement
Water-Pump Inspection & Service
Shift Mechanism Inspection & Adjustment
Gearcase Cleaning
Pressure & Leak Testing
Lubrication & Final Assembly
PARTS & COMPONENTS RESTORATION
WaterHogsWorks restores individual parts and components used throughout classic Kiekhaefer Mercury outboards.
Original components are preserved whenever practical. Parts are carefully cleaned, inspected and refinished with attention to maintaining the appearance and character of the original engine.
Component restoration may include:
Hardware Cleaning & Restoration
Brackets & Linkages
Throttle & Shift Components
Fastener Cleaning & Preservation
Small-Part Cleaning & Refinishing
Surface Preparation
Component Inspection & Reassembly
Whenever possible, we believe in restoring a serviceable original Mercury component rather than replacing it simply for cosmetic reasons.
ELECTRICAL & WIRING HARNESS RESTORATION
WaterHogsWorks provides restoration and rebuilding of electrical systems and wiring harnesses for classic Kiekhaefer Mercury outboards.
Decades of heat, oil exposure, corrosion and age can leave original wiring brittle, damaged or unsafe. Internal and external wiring harnesses can be rebuilt while maintaining the routing and appearance appropriate to the original engine.
Electrical restoration services may include:
Internal Wiring Harness Rebuilding
External Wiring Harness Rebuilding
Wiring Inspection & Troubleshooting
Damaged Wire & Terminal Replacement
Connector & Terminal Inspection
Starter & Charging Circuit Inspection
Continuity & Electrical Testing
Harness Routing & Final Installation
Original harnesses can be evaluated and used as patterns when rebuilding wiring for selected classic Mercury models.
HAVE A CLASSIC MERCURY PROJECT?
Whether you need a complete restoration, precision machine work, a rebuilt powerhead, or help with individual components, we’d be glad to discuss your classic Mercury project.
Tell us what you have, what you’re trying to accomplish, and the condition of the engine or components. Photos are always helpful when evaluating a project.