Nice work!

Thank you very much...

For those interested in replacing the cuddy side light bulbs from Halogen to LED and concerned about brightness, here's a reference to there soft white output compared to Bright White bulbs:



I had to buy 10 of these in bulk to get a good price, if you'd like to purchase some for your boat let me know, I'll sell off what I don't need cheap, but wait till I get them installed and post a pic of their brightness first.

Thanks for the writeup. I'll tackle mine here soon.

Got the cabin bulbs early, so in they went. I'm real happy with the softer white compared to the swivel lamp bulbs (blindingly bright). Here's a couple of pics, please note that the camera makes them out to be much brighter than they really are, just think soft lighting because that's what it's exactly like.





This pic is with just the 2 swivel lamps on:






SOLD-SOLD-SOLD to Revd Up...............If interested I have 5 of the cabin LED side light bulbs extra (had to buy 10 pcs), used 4 and keeping 1 for a spare. I'll sell those for what I paid + the trip. Let me know if your interested.

If you need some here's the eBay link:
http://www.ebay.com/itm/G4-G9-1-5W-4...XGTPCmnF3RPtCw

Per some info BUP shared, replace this filter with a 100 Micro unit, nothing smaller or you'll starve the fuel system.If any of you are using one of these fuel filters............don't waste your money on replacing it. I pulled mine to replace it and something rattled inside.............I thought, well...might as well open it up to see what it was. The plastic screen cylinder had come off so there was no filtering at all. here's some pics of what Merc charges you $50 for, it's really a P.O.S. for a filter. Looks like a fuel injector cleaning is in order from what was in the filter can.......

Update on the fuel filter situation since the wake up call from BUP on my original plan, ordered an Aeromotive 100 Micron Filter as associated fitting to make it all come together. Limited fitting available to do what I needed so some machining is in order to drill and tap the 2 "O RING" caps and turn them into adapters for 3/8 NPT fittings. Due to limited room I had to plan a compact install, here's a sketch of how it's gonna go in:

Fuel filter and associated fittings installed:

-10 AN O Ring CAP/PLUG FITTING



-10 CAP/PLUG DRILLED & TAPPED FOR 3/8 NPT THREADS



1/2" FUEL LINE BALL VALVE WITH HOSE FITTINGS



AEROMOTIVE 100 MICRO FILTER INSTALLED W/THE MODIFIED -10 AN O RING CAPS



FINISHED INSTALL

Nice clean install. What type of cool fuel setup does your 03 have? My 06 has the gen 3 style with cartridge filter and disc pad below the cart filter. Just wondering why the need for the additional prefilter?

Thank you,

I honestly couldn't tell you. I'm still learning what it has and doesn't. It's a base 2003 496 MAG. I followed the fuel line from my new prefilter and it goes into the suction pump then onto the spin on filter, didn't see anything obvious related to cooling the fuel, but hey I'm still learning, totally different as I came from Outboards.......

I've enjoyed all the posts and project updates. It's great to see the dedication to the new projects. That said first, I do have some concerns on the fuel filter installation for your consideration.
1. The previous owner must have installed the Mercury canister filter in that bulkhead location as this is not standard. This kind of filter has been installed between the high pressure pump and fuel rails by Mercury. Is this additional filter called out for your 496 (right?) configuration? I'd take a look at Mercruiserparts.com to see if it's required.
2. I assume that you are still using your water separating filter prior to this filter and not just the one filter? It looks like you are.
3. So here's my concern with this set-up:
a. The 496 only has an electrical pump. Electric pumps push fuel much better than pull it. That's why Merc Racing had to use the problematic belt driven fuel pump/sea water pump to feed their motors.
b. So looking at the diagram, my concern is that you added a second filter with three 90 degree fittings ahead of your fuel pump which isn't great at pulling fuel. This restriction may cost you performance and you also want to avoid anything that can even remotely, cause you to run lean.
4. So here's some suggestions:
a. Consider removing the filter outright if it's not called for by Mercury. Why add complexity and another point of failure?
b. Consider plumbing it between the fuel pump and fuel rail if you want the extra protection.
c. If you really want to stick with the current bulkhead mount second filter configuration. Make it easier on your fuel pump by eliminating the 90 degree fittings completely or replace with better flowing fittings.

Thanks again for all the progress posting and I'll be anxious to hear about when you first get it in the water and how the inside steering set-up work out.