So engine is at the machine shop and I completely disassembled the Bravo1 transom assembly and I'm i little worried. A new complete unit is $4K+ which totally smokes my budget but on the flip side I do not need a leak and will sink all my work to redo this boat. Luckily the transom is solid but I want your opinions on this.

I am going to have it soda blasted I think and see what it looks like afterward but I'm skeptical I think it is savable but I also don't want to waste money on something that is going nowhere.

The whole project started with a leaking steering pin which escalated to a bad head gasket and now this LOL B.reak O.ut A.nother T.housand LOL

There's always lightly used ones that pop up for $1500ish. If you can't swing a new one then a nice clean used one would be my recommendation. I wouldn't reinstall one that looked like that when you consider all the work to re-do it and what's at stake if it's not right.

Also, here's a vendor selling new for <$3300
https://leadersrpmshop.com/mercury-m...-hp-6511002nz/

And here's a used HP assembly for 2200

https://www.ebay.com/itm/17560288174...Bk9SR-TRsJfPYQ

Another option:
https://www.ebay.com/itm/19559139319...Bk9SR-bRsJfPYQ

Pretty much anything is salvageable if you throw enough time or money at it. Depends on how much value you put on your time. Repairing the seal area is going to be difficult. And a proper paint job is not something you are going to be able to do with spray cans.

Forgive the clearly self serving commercial plug but we do have some new, complete ready to install transoms for $3375. Cylinders, hoses, ready to go.

I was going to have it cleaned up and powder coated, I also have a good friend who owns a body shop so the painting part I'm not worried about. My concern is it not leaking, I was going to install a new JR marine stainless steering pin along with a complete rebuild but my fear is the aluminum is to far gone.

I would let it soak in a big bucket of CLR to remove any mineral deposits and see what you have left.

My concern would be leaking around the seal area.

My guess would be a bucket of CLR LOL

thats my fear. Anyone ever powder coat one of these before? bad idea for any reason and better off to paint it?

Buddy of mine bought one from you not too long ago for a repower project on his boat.

https://www.offshoreonly.com/classif...te-o82803.html

I think the only issue we ran into is the water inlet neck not seating properly and needing a different one? Wouldn't seat flush against the o-ring.