Seized e-box brackets - any suggestions?

[SJBrit]

I'm not talking about the nuts - they span right off. But the stainless e-box bracket is actually seized on onto the lug on the e-box. I'm soaking with WD-40, but does anyone have any other suggestions? It's hard to add heat there because of the cable running out of the e-box close by, but I'm not sure that heat would help much anyway. I'm really concerned about breaking the casting on the e-box if I get too physical with it.

 

[keefer]

Just tap on it lightly & wiggle it around until it starts to break free. Galvanic corrosion gets pretty bad there and the aluminum oxide is just jamming up the works for you. Someone should make some brass inserts for the e-box lugs to minimize the stainless to aluminum contact. Lets go ride soon, that AL water is bound to be warmer than this TN ice water.

 

[steve1981]

why dont you just undo the bolts that go thru the dash. once you get the box out it will be a little easier to work on getting the bracket off, you may even find it possible to do whatever you got to do without removing the bracket. also cold will work better than heat in this situation. they make a product for that but you can use a can of compressed air called duster (keyboard cleaner) turn it upside down and spray directly on the bolt up close. it will instantly freeze and cause the metal to contract and break the corrosion in the process. may take a few tries. use some anti-sieze on all your nuts and bolts when you put your stuff back in. good luck

 

[vomitspot]

try washing your ski and not letting it dry with the hood on
sorry i had to
yea pull the 4 6mm thrugh hull bolts
once ebox is out of the hull just tap them like your unscrewing them
once they are out clean out the corrosion with a file

 

[SJBrit]

Hmmm... cold sounds like an interesting idea. The e-box is out of the ski - just trying to get it all cleaned up.

 

[waxhead]

Thats a great idea steve, did you know there was a product thats designed to cool loctite make I think they actually just call it frezze

 

[#ZERO]

I use a pressure washer with a zero degree nozzle tip aimed point blank against the stud to remove the corrosion buildup and the box will come right loose.

 

[FlightPlanDan]

It's not just you! Been there. It sux!
Even after removing the dash and getting the box out that way, there are still 2 screws that you can't get at!
All I can say is "take your time".
WD40 is for water displacement. Try PB or another solvent/penetrant.
To be honest, I got to the point that I was ready to buy new brackets, (cause I was bending the crap outta them), and they finally gave a bit, then back and forth...back and forth....
again...take your time.

The "freeze" thing is interesting. There is actually some stuff available for this purpose. I tried it with no results... I followed the instructions....(I was also afraid to use heat)
X2Frank got it from work...can't remember what it was called.

 

[mkivbren]

I'm in the midst of this too... just soaking with pb blast right now. When I get them out I'm going to slightly open up the casting hole and then clean up the studs and shrink wrap sleeves on them to isolate the dissimilar metal corrosion. And anti seize just about everything.

 

[FlightPlanDan]

I'm in the midst of this too... just soaking with pb blast right now. When I get them out I'm going to slightly open up the casting hole and then clean up the studs and shrink wrap sleeves on them to isolate the dissimilar metal corrosion. And anti seize just about everything.

Anti-seize is a good idea.
I also drilled out the aluminum casting a bit, once I got it apart.
Marine greased it in a big way as I put it back together.
And (now) pay special attention to those brackets when doing the freshwater washdown.

 

[SJBrit]

Just tap on it lightly & wiggle it around until it starts to break free. Galvanic corrosion gets pretty bad there and the aluminum oxide is just jamming up the works for you. Someone should make some brass inserts for the e-box lugs to minimize the stainless to aluminum contact. Lets go ride soon, that AL water is bound to be warmer than this TN ice water.

I bet I can find some brass bushings that fit - that's a good idea. I have some major rebuilding to do before I am riding, but when I get my ski back together it's going to be a backflip machine, so I'll need to come up there and ride the General Jackson with you guys!

 

[steve1981]

Thats a great idea steve, did you know there was a product thats designed to cool loctite make I think they actually just call it frezze

yeah i got a can of it here at the house. i just mentioned the duster because some people dont have a place to get this stuff. and the duster works great in a pinch and is readily available

 

[Tedwin]

i had this exxact same thing happen to me when I took my ebox out a few weeks ago for the MSD. Had to get it out the same way you did and then put the frozen bracket in a vise and put a lot of muscle into turning it. It bent a little bit but I got if off. i just bent it back before I was done.