Towards the end of least year we broke a small drill bit off trying to clear debris from the Merc lower unit, the mph water intake (dnt know the correct term.) Dumbass move, ya I know...
Anyway, any ideas how to get this out or solve the prob w/ out tearing it apart?? I know im not the only one whos ever done this.

Tearing the drive apart won't help other than making it more easier to handle. That path is unaccessible from inside. Might try to blow air backwards from the yellow disconnect, but not sure that would do anything. Carbide drill won't work as it will just walk off into the softer alum and then snap off when it binds with the broken drill. Now you have 2 broken drills.

Is it broken off flush or inside?
Flush, might be able to use tweezers with small points to
grab each side of the drill body.
Don't know if a LH drill would catch and dislodge the broken drill. Might be worth considering.

Need some type of acid to speed up the rusting of the drill till it falls out that does't effect the Alum.

that's a tough one. good luck

Unfortunately you are SOL!! We did the same thing and it will not come out. We ended up installing a pick up on the transom.

Or you could buy a GPS Speedo...I know a guy that will give you a great deal!!

That would be my suggestion.. GPS speedo, but it may show a few mph slower?? But will be more accurate, then you will have to spend money on more speed parts to get your speed back.. I bet there are a few here that can help in that area.. then when your drive breaks.. Give me a call..


Hope this helps??!!

There is a chance that the speedo might still work. It depends on how the bit is broken in there. Getting it out is probably out of the question without getting destructive on the lower. The transom mount pickup is probably the best option.

Rene

what about drilling another hole just above the old one into the same chamber. thats if it goes straight up?

thanks for the ideas guys, i really appreciate it.

Did the same thing about 15 years ago. I was lying on my back carefully drilling out the debris when my son (in diapers at the time) crawled up and kneed me where it hurt. I jerked and the bit stayed. I ended up carefully clearing some material away from the case with a die grinder at the pickup hole and was able to get needle nose on it to remove.

There is a stainless tube inside the case; this is where your bit is broke off. If you trim the case at the entrance you will find a way to grab it and remove. Once that is done put something soft in the hole and fill with JB weld then drill the soft material out. A spray can straw is about the right size.

If you had twins you could change speedo pickups to the other drive.