The Bravo Shift Cable from my engine to my drive was shot. It was the old style with the smaller diameter fitting at the drive. The new cable has a 7/16 inch bore. Mercury says I must use their drill alignment tool to ensure drilling a smooth, straight hole. I think I can get it really really close on my own.

What are your thoughts? If I am a tiny bit off will I screw up my drive?

Thanks!

Stephen

Is it really worth taking a chance??? I mean how much can a new housing cost anyway?

A bell housing about $450.00. If it is the hole where the flanged nut and seal washer goes it dosent seem to big a deal, it is only aluminum and only 1/2" thick at the max. How small is your hole to start with? Just drill in steps smaller bits up to the 7/16" size. It would seem to me you could only make it off by a 1/16" or so by being sloppy. I dont think it would be a problem as the shifter core wire can flex a little.

If you step-drill in several increments using "fresh" drill bits (not worn in the margins) then the drills will follow the existing hole. If you use worn bits, they can lead off significantly. Use WD40 or kerosene in the hole to cool and lube the drill bit.

Thanks for the responses. I only need to increase the diameter by 1/16 or 3/32. I am trying to get a tech at the marina to handle it this weekend but they are very busy this time of year. I just didn't want to wait for them and then see the tech come over with a 7/16 inch drill, punch it through in 10 seconds (without alignment tool) and slip the cable in.

It seems that sometime in the early-mid 90's Mercury increased the size of the cable end. The nuts on either end are the same size. All new cables come with the larger end and all old drives must be enlarged

I will head over there this afternoon. If they haven't done it I will take another look at doing it myself or offer them $$ to borrow their tool.

Thanks!