BARELY - A - WAKE

(Group 26)
Johnson Outboard Motor

DUE: Wednesday, May 7th

Group Members:
Trent Bellingham
Nick Davis
Alex Sperlich
Joe Tigges
Brendan Urke
Brian Weaver

Table of Contents
Picture of Project
(2)
CREO Rendering
(3)
Table of Contents
(4)
Introduction
(5)
Applications
(5)
Design Considerations
(6)
Calculations
(6)
Calculations analysis
(6)
Bill of Materials
(7)
Assembly print/exploded assembly
( )
Subassembly and Exploded Subassembly A
Dimension detail drawings
( )
Subassembly and Exploded Subassembly B
Dimension detail drawings
( )
Subassembly and Exploded Subassembly C
Dimension detail drawings
( )
Subassembly and Exploded Subassembly D
Dimension detail drawings
( )
Subassembly and Exploded Subassembly E
Dimension detail drawings
( )
Subassembly and Exploded Subassembly F
Dimension detail drawings
( )
CREO Rendering with Modified parts
( )
Stock Part list
(10)
Stock part line drawings
( )

Introduction
The assembly of choice for our group is an outboard boat motor that belonged to Joe
Tigges. The broken motor belonged to Joes father but, he was willing to part with it for his sons
Engineering Design Project. Our group came to agreement that we would disassemble the
motor and draw it in CREO because the other two available options, an old ice auger and a
broken lawn mower, had too few parts to make them worth pursuing.
The history of the outboard motor dates back to 1800s. In 1880, electrical engineer
Gustave Trouv of France patented the first outboard motorboat. It had been developed 10
years previous. The battery used to power this motor was a lead-acid differential charge battery
and was first implemented to power a tricycle. Below is a drawing from www.insideyachting.org
of Gustave Trouvs original outboard motor. The text below the drawing translates from French
to read: View of the engine rudder propeller by Mr. Gustave Trouv. The text in the middle of the
drawing (above the line) translates from French to
read: Water level. Within 20 years of Gustave
Trouvs patent for an electric outboard, about 25
brands of American petroleum powered outboard
motors were in existence.
http://insideyachting.org/wpcontent/uploads/2012/10/Trouve-prop-drive.jpg
Applications
Boat motors have only ever been useful for one
task; propelling a boat through the water. Our
particular motor was used on a sportsman fishing
boat. When it stopped working, the owner bought a newer one rather than get the old one
repaired.

Product Considerations
When working with the motor, we had to consider several aspects of the project that might be
troublesome or an obstacle. Firstly, we had to consider the storage of our unit as it was very
large and smelled of gasoline. The motor spent most of the time in Trent Bellinghams room in
an enclosed tote. The second consideration we made was about where we would disassemble
the unit. For this, we utilized the Reid-Johnson Hall Basement, which accommodated our space
needs nicely. Lastly, and perhaps most importantly, we had to make sure that the motor had a
sufficient quantity of parts for us to draw in CREO. The actual number of parts that we
extracted from the motor was 74.
Modification / Design Change
As others did in the past, we attempted to make alterations or improvements to the original
design. This project requires us to select six parts to change approximately 60 percent from the
original item. The six parts that we plan on redesigning include the propeller, whale tail of
propulsion system, piston heads, middle shaft, air intake of the engine cover, and cranking tilt
for motor positioning.

Calculations
Part
Number
B3004
B1006
B1001
B3005
E1005
E1004
B3002
E1008
E1007
E1006

Measured
Weight
86.6 g
59.4 g
226.7 g
49.8 g
55.4 g
52.0 g
42.6 g
142.4 g
128.5 g
127.5 g

Estimated
Volume
40 cm
24 cm
288.9 cm
12 cm
6 cm
5 cm
16 cm
18.025 cm
45.9 cm
45.5 cm

CREO Calculated
Weight
283.166 g
334.342 g
3693.14 g
53.61 g
56.194 g
55.977 g
22.954 g
156.575 g
481.49 g
461.69 g

CREO Calculated
Volume
35.39 cm
55.72 cm
615.52 cm
8.935 cm
7.024 cm
6.997 cm
2.869 cm
19.572 cm
60.186 cm
57.711 cm

The variance in the calculation may have derived from the incorrect value being entered into
Creo for calculations of mass or from the inaccurate solid modeling.

Part List
6

Part #
a1000
A100
1
A100
2
A100
3
A100
4
A100
5
A100
6
A100
7
A100
8
A100
9
A101
0
A101
1
A101
2
B1000
B1001
B1002
B1003
B1004
B1005
B1006
B1007
B1008
B1009
B1010
B1011
B1012
B1013
B1013

Quantit
y
Name
1 Drive shaft assembly

Material
varied

1 nose cone

Steel Alloy

1 propeller

Steel Alloy

1 drive shaft gear 1

Steel Alloy

1 drive gear slitter

Steel Alloy

1 drive gear spacer

Steel Alloy

1 drive shaft gear 2

Steel Alloy

1 lower drive system seal

Steel Alloy

1 vertical drive shaft gear

Steel Alloy

1 horizontal drive shaft

Steel Alloy

1 vertical drive shaft

Steel Alloy

1 gear placement rod lower half

Steel Alloy

1 gear placement rod upper half

Steel Alloy

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Cast iron steel

Cast iron steel
Cast iron steel

Engine sub assembly

Flywheel
Inner Engine wall with spark mount
Outer Engine wall with spark mount
Crank case
Engine wall with carb mount
Exhaust cover
Rope guide
Flywheel engaging gear
upper Starter Mount
Lower Starter Mount
Outer starter Handle grip
Inner Starter Handle grip
Fuel Injector
Water Regulator

Cast iron steel

Cast iron steel
Cast iron steel
Cast iron steel
Plastic
plastic
Cast iron steel
plasic
Cast iron steel
varied
steel

B2001
B3001
B3002
B3003
B3004
B3005

1
1
2
2
2
2

block
Crank
piston rod-lower
piston rod-upper
Piston head
Spark plug

Aluminum
Steel
Steel
Steel
Steel
steel/plastic

C1000
C1001
C1002
C1003
C1004
C1005
C1006
C1007
C1008
C1009
C1010
C1011
C1012

1
1
1
1
1
1
1
1
1
1
1
1
1

Carb Assembly
Carb upper block
Carb lower Block
Choke arm
fuel intake Arm
fuel injector jet 1
fuel injector pin
fuel injector jet 2
float
trottle ajustment
choke pull
choke guide
Idle rpm adjustment

Varied
Steel
Steel
Steel
Steel
Steel
Steel
brass
rubber
plastic
plastic
metal
brass/plastic

D100
0
D100
1
D100
2
D100
3
D100
4
D100
5
D100
6
D100
7
D100
8
D100
9
D101
0

1 Body Assembly

varied

1 lower half outer casing

steel

1 lower case drive guide

steel

1 lower case oil pan

steel

1 upper half outer casing

steel

1 lower engine casing

steel

1 upper engine cover

steel

1 upper case drive shaft guid

steel

1 water pump blade

rubber

1 right half throttle grip case

steel

1 left half trottle grip case

steel

E1000
E1001
E1002
E1003
E1004
E1005
E1006
E1007
E1008
E1009
E1010
E1011

1
1
1
1
1
1
1
1
1
2
1
1

Motor mount assembly

steering column
steering case
gear shift
spring mount
spring tension mount
bottom steering column w/ holes
bottom steering column w/o holes
Tilting lever
Boat clamps
Trim handle
Mount lock

Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel

F1000
F1001
F2001
F2002
F2003
F2004
F2005

1
1
1
1
1
1
1

Throttle adjustment grip arm

throttle adjustment grip
throttle shaft 1
throttle shaft 2
shaft receiving gear
shaft force transfer gear
throttle shaft L-arm

varied
varied
Steel
Steel
Steel
Steel
Steel

Stock Part List

Name/Dimensions
1/8-24, 1/4" long
1/8-40, 1/2" long
screw-1/4" follower. 1/8-32
1/16-48, 3/16" long
3/16-24, 5/16" long
1/4-24, 1.5" long
1/4-24, 3/4" long
1/4-24, 7/8" long
1/4-24, 1 5/8"
1/4" washer
1/4-24, 1 1/4" long
1/4-24, 5/8" long
3/16-28, 7/8" long
3/16-28, 5/8" long
3/8-32 (7/8" thread) 6 1/4" long bolt
1/4-32 counter sunk flat head 1.5" long
1/4-24, 6/8" long
1/4- 24 , 1/2" long
3/16-40, 3/4" long
3/16-32, 3/8 long
3/8, 9/16" long
1/4", 7/16" long

head type
Flat head
Flat head
follower with Flat
head
Flat head
Hex flathead
3/8" hex
3/8" hex
3/8" hex
Flat head
washer
Flat head
Flat head
Flat head
Flat head
Hex
counter sunk
flathead
7/16 hex
counter sunk
flathead
Flat head
Flat head
hex nut
hex nut

our stock
number

Qt
y

SP001
SP002

1
5

SP003
SP004
SP005
SP006
SP007
SP008
SP009
SP010
SP011
SP012
SP013
SP014
SP015

1
2
1
8
3
2
4
10
2
4
15
2
1

SP016
SP017

1
4

SP018
SP019
SP020
SP021
SP022

2
1
1
1
1

10

3/16-24, 1 1/4" long

1/4-20, 1" long
3/8- inner plastic washer-1.5" total
3/8 inner, 3/4" total
1/4 inner, 5/8" total
1/4-24, 3/8" long
1/4-24, 3/4" thread length2, 5/8" long
1/2 diameter, 1/4" hole
3/16-24, 11/16" long
piston bearing rods- 1/16 diameter, 5/8"
long
1/2" hole, 1 3/16 total
1/4-24 5/8" long
1/4-24, 3/4" long
Carb Gasket Nozzle to Bowl
Carb Gasket Bowl
Carb Gasket
Carb Throttle Valve
Carb Choke Valve
Carb Follower Link
Carb FLOAT VALVE AND SEAT
exhaust gasket covers
exhaust cover-inner
cylinder head gasket
water intake gasket
Rubber hose
Engagement Gear Wire Clip
1/4-20, 13/16" long
1/4-20, 1 1/2" long
1/4-20, 1/2" long
7/32" inner, 1/2" total
1/4-20, 5/8" long
1/4-20, 7/8" long
1/4-20, 15/16" long
Piston Rings
Piston Rod
Piston G-Clip
Carb Hinge Pin
Throttle Shaft Spring
Flywheel Nut Cap
throttle handle inside guide
throttle arm joint cover

Flat head
Flat head
washer
washer
washer
Flat head
3/8 hex
lock washers
1/4" Hex flathead

SP023
SP024
SP025
SP026
SP027
SP028
SP029
SP030
SP031

1
1
1
1
1
1
2
2
4

bearings
washer
5/16 hex
Flat head
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
5/16 hex
3/8 hex
3/8 hex
washer
7/16 hex
5/16 hex
3/8 hex
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant

SP032
SP033
SP034
SP035
SP036
SP037
SP038
SP039
SP040
SP041
SP042
SP043
SP044
SP045
SP046
SP047
SP048
SP049
SP050
SP051
SP052
SP053
SP054
SP055
SP056
SP057
SP058
SP059
SP060
SP061
SP062
SP063
SP064

50
2
2
2
1
1
1
1
1
1
1
2
1
1
1
5
1
4
1
4
2
4
1
1
6
2
4
1
1
1
1
1
1

11

throttle handle collar

shift rod upper
mount reverse lock spring
throttle L arm pin
grip to bock spring
tilting lever spring
pump to cylinder gasket
armature plate
throttle handle washer
throttle handle spring

irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant
irrelevant

SP065
SP066
SP067
SP068
SP069
SP070
SP071
SP072
SP073
SP074

1
1
1
1
1
1
1
1
2
1

12