Volvo Penta 3.0 GSP-C Starter Motor Mounting Holes Repair Jig

This jig is used for the repair of oversized starter motor mounting holes on a Volvo Penta 3.0 GSP-C block. Using JB-Weld to reform the holes, the jig provides precision alignment of new holes for retapping and mounting of the starter motor.

The model shown here is drafted based on careful measurements from the starter motor mounting plate. In effect, it provides an identical sectional profile of the starter motor.

For use, the oversized holes are preparred per the JB Weld instructions. In my case, I used a large tap (Figure 3) to score the holes for better adhesion of the epoxy. The jig is then positioned in place with the guides protruding through the holes (Figure 4). while referencing the indentations on the model as a guide to assure proper alignment. The jig should align perfectly, allowing space for the plunger to be fully inserted (Figure 5). Once positioned, JB-Weld is packed around the shaft. The plunger is then pushed into position to squeeze the weld into place (Figure 6)

The print is done using PLA which takes advantage of the inability of JB-Weld to adhere to this material, thus allowing the jig to slide out after the curing is complete.

Note, the jig may work with other engines that use the Volvo Penta Start Motor Part Number 3885317 or compatible parts

Images:

1. Model showing relationship of jig to engine sectional.
2. Complete printable model
3. Close-up of the two over-sized holes. Use of the tap was to rough holes for better adhesion of the JB Weld.
4. Jig clamped in place with guide rods revealed.
5. Plungers inserted to insure alignment.
6. JB Weld packed in and plungers seated in place to form the proper thru-hole diameter.

This is a work in progress. I'll post the final results soon.