removing rusty coupler set screws

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Victoria28

.
Mar 22, 2008
25
Catalina 28 Victoria
Hi, I have a '92 Catalina 28 - Universal M3-20 engine with Hurth HBW 50-2R transmission and what appears to be the original coupler. I need to remove this coupler and have purchased a new one from Catalina. The problem is getting the heavily rusted set screws to back out. I have carefully soaked all the bolts with a petroleum based penetrating oil. I have had success with loosening the 4 bolts that connect to the transmission, but the set screws are giving me a real fight!
After much scraping & brushing to remove as much of the rust as I have been able to so far it seems like the square heads are now a slightly smaller width than original. As you can see in the attached photo it looks like I'm going to destroy the head and/or break off the screw If I can't find a way to loosen them up.
So please any ideas - helpful hints?
Thanks, Bill
 

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Moody Buccaneer

Moody Buccaneer

.
Oct 25, 2005
735
Catalina 30 Banderas Bay, Mexico
Victoria28 said:
Hi, I have a '92 Catalina 28 - Universal M3-20 engine with Hurth HBW 50-2R transmission and what appears to be the original coupler. I need to remove this coupler and have purchased a new one from Catalina. The problem is getting the heavily rusted set screws to back out. I have carefully soaked all the bolts with a petroleum based penetrating oil. I have had success with loosening the 4 bolts that connect to the transmission, but the set screws are giving me a real fight!
After much scraping & brushing to remove as much of the rust as I have been able to so far it seems like the square heads are now a slightly smaller width than original. As you can see in the attached photo it looks like I'm going to destroy the head and/or break off the screw If I can't find a way to loosen them up.
So please any ideas - helpful hints?
Thanks, Bill
Click to expand
Wet towel under coupler to protect the hull and hoses. Propane torch on the coupler until hot enough to cause the water you dripped from the towel to sizzle. Tap screws with a hammer while trying to remove them. If they don't come out, apply more penetrating oil, let cool overnight and try again.

Have a fire extinguisher and a helper close by and wear eye protection.

If twice doesn't get it done, you may have to drill the set screws out. Good news, you done have to worry about saving the threads in the coupler!

The heat and tap trick should work if they are ever going to come out.

Randy
 
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