I replaced my gimbal ring on my 2000 bravo one drive, using the mercruiser method of access holes. Every thing went good until it came time to tap the holes. In the process of tapping the hole I cross threaded it. Anyone have a subjection as on how to deal with this problem.

I dunno how much material. (not familiar with the process) but you can put a thread insert in there (larger tapped hole the existing hardware), either use a helicoil or keensert.

what size is that thread they tell you to tap,

you can just tap the next biggest size up from that

the hole is 1 1/8".

This might be too late an answer for your job, but just get the threads in good enough shape to hold the threaded plastic plugs securely. When putting in the plugs, use a good, underwater and aluminum safe sealent. Dont use 3M 5200, use something that stays somewhat flexible and can be removed. These holes will not have to withstand much water pressure, and are not stressed: your just keeping out the water.

It's only a pipe thread, you could just tap larger and use a larger plug. But the taps aren't cheap. I would go the sealant route, JB Weld or Marine Tex would work fine. Remember it's not submerged, just gets wet sometimes. Also with a pipe tap if you can restart the tap straight, thread it in farther, the tap gets bigger as it gets near the end, cleaning the damaged threads. Then just get a longer pipe plug and screw it in farther, as long as it doesn't hit the steering in a turn.

Actually, it can be underwater depending on the boat, but not that far underwater. About 6-12 inches constant submerged is the most I have seen. Your idea of threading farther is good, but he might need to remove the swivel pin, steering arm and gimble ring to get it much further as the tap may bottom on those parts. Mostly likely the reason he tapped it was to fix a pin / steering arm / ring problem.

This might provide more info on the process:
http://www.mercstuff.com/gimbalringinst.htm

There is a guy who has a website that sells special tools / kits for this sort of job- I wish I had his special wrench before I did my Alpha SS like this, as it would have made the job far easier. I cannot find the link at the moment but if I find it I will post it.

I was able to get the plug to fit very snug with the cross threading and about 3 or 4 good threads at the back of the hole. I then sealed the edges with a marine silicone. The other side threaded perfect, so no worries there. Thanks again for all your suggestions.

One other option, in the event that the plug falls out is to install a grab handle on the transom. Then you can have your buddy, or if married, your wife, hang over the transom holding the handle with one hand and using the thumb from the other hand to plug the hole while at rest or getting on plane. Once on plane the transom assembly would be above the waterline so they could return to the cockpit for an enjoyable day of boating. You could also install a drink holder on the transom so they have a place for a frosty beverage while manouvering through those pesky no wake zones. If you're boating with your buddy and he never coughs up at the fuel pump but always rides shotgun, this would be a perfect task for him. To show your appreciation you could purchase a swim platform, if there isn't one already installed, and strap a cooler to it. This would be for his personal beer supply. After a few outings, and you find he is doing a great job of stopping the ingress of water into your bilge, splurge a bit. Show him how impressed you are. Harbour freight have great prices on ear muffs, a must for your buddy or wife if your running dry exhaust out the transom. Also maybe a resperator. Those fumes will start to get to them after a long no wake zone. Happy boating.