Only some minor items left to attend to. If you came in on this page, page 1 is HERE
(click on images for full-size pictures)

With the success of the 10HP Lightning KE-7, Mercury engineers set upon a project to create a new motor to revolutionize big outboards. This market was still dominated by the leftover WW II OMC quads and opposed twins, designed in the late 20's and early 30's. A number of designs were tried, opposed 4's, V-4's, square fours, and big twins, but the final design settled on was the alternate firing inline 4. This engine was introduced in 1949 as the model KF-9 THUNDERBOLT. These motors were not real popular in the first few production years as they were expensive and had no rewind or gearshift, these big "25" HP motors are scarce to rare and are very popular with collectors.

Added the rest of the details up front and the steering bracket. I didn't like my original fuel line routing so reworked it some to simplify, here we have got the hoses all installed from point to point. I have not hooked the gauge up yet, all that would be required to do so is to install a tee in the loop at the bottom of the line from the pump to the carburetors. I don't want to get this full of gas at this time, just leaving it for good looks. This was my Christmas Day project.

The tiller handle bracket contains a suction pump for priming the motor as well as this fuel pressure gauge so you will know when there is enough gas to the carbs. These old engines used a threaded fuel connector, one of which I don't have so I just will run the line out through the lower hole. This hole is usually covered with a capplug, the mechanical tachometer drive cable should you have one would pass through here.

The final touch, a BRAND NEW Michigan 3 blade propeller.

All the work finally comes together. This sure was a challenging project, a motor that started out as rough as this one requires that everything be renovated in order to make it a usable unit. The effort was all worthwhile for me.

Still a few loose ends but for appearances sake she's done. I tried to make the external appearance as close to original as possible rather that too polished and shiny. Rewarding effort! I have many fond memories of watering my eyes with these Thunderbolts back in the dark ages when I was a kid!

Mercury-built WIZARD 6 HP 1946

Unfortunate circumstances subjected this KF to a salt water bath courtesy of hurricane IVAN that devastated my waterfront place here in Florida. I rinsed the KF out and resprayed it with fogging oil. It has, as of Dec 2009 never been started. Some damage (gage, pump) is irreversable but I am heartened by finding my MARK40H had no internal damage after I had given it similar treatment.           Hope you enjoyed this project as much as I did! 10/2009, The Wizard WD4S has now been restored - hurricane IVAN destroyed the original powerhead so I modified a KE4 to fit, probably the only WD4S with a Phelon magneto!