How Are Powerheads Remanufactured?

How OBR Remanufactures Powerheads: A Step-by-Step Look at the Process

At OBR, the term "remanufactured" means more. While you may hear it and think of a used powerhead that has simply been repaired and cleaned, the OBR process is much more detailed. We make sure that our remanufactured powerheads are good as new before they ever end up back on the water.

So, how exactly does the remanufacturing process work? Follow along as we guide you through the first inspection of a core to the last strip of tape placed on its packaging.

Step 1: It Starts With a Used Core

From the top, the remanufacturing process always begins with a used core. A core is the powerhead or gearcase of an outboard motor, separated from the rest of the motor. When a customer takes their boat in for repairs, depending on the severity, mechanics will often have to replace an entire component of the outboard motor. When that happens, the damaged powerhead or gearcase is discarded. At service centers where mechanics see hundreds of boats a year, it's easy to imagine how this leads to a hefty collection over time.

OBR incentivizes dealers to send back those cores by offering real cash reimbursements for them. It's important that we receive OEM powerheads because having a reliable starting point is the first step to ensuring our product quality is consistent.

When a core first arrives at our warehouse, our team gives it an initial inspection and then disassembles the unit. The goal is to make sure that the main components are useable. If a core is completely destroyed, it gets discarded.

Alternatively, if a core or some components are deemed acceptable, those parts will be added to the core supply and are processed for production.

Step 2: Complete Disassembly

As the core is disassembled, OBR technicians perform a more detailed inspection to evaluate if the units are buildable. Once the unit is deemed workable, the disassembled parts are put through a precise inspection process using media blasting followed by a third inspection.

This complete disassembly and cleaning process is necessary because at OBR we don't just fix the part of the motor that failed. We want to make sure our customers take home a unit that is just as reliable and high quality as an OEM unit. The components of an outboard motor naturally wear over time, and if the repair process is focused solely on the part that failed, it's likely you might overlook another component that is on the verge of failure. At OBR, we recognize that the initial failure could be the tip of the iceberg. If you fail to perform a complete disassembly, you might not catch those details, putting worn or bad parts on a unit going to a customer.

As our technicians take apart powerheads, they search for parts that show any signs of wear or damage, making sure that each component kept is fully functional and ready to be given new life.

Step 3: Cleaning the Components

After disassembly and close inspection, the individual parts are sent to another set of techs for cleaning. This cleaning process is extremely precise, allowing technicians to see the condition of the components as clearly as possible. Sandblasting is one of the ways OBR thoroughly cleans individual parts, which removes any residual oil or debris. Detailed cleaning is necessary before moving forward with the remanufacturing process because it allows technicians to see the true condition of each.

Step 4: Machining and Preparing the Block

After the powerhead is disassembled and cleaned, the blocks are sent to our machinists to go through the boring and honing process. Each powerhead is bored to the next oversize to ensure proper roundness and taper. IT is then honed with the proper diamond stones and plateaued to achieve a perfect cylinder surface. After going through both processes, the block of the powerhead will match OE specs up to the thousandth of an inch, making it nearly impossible to differentiate from a new unit.

Step 5: Determining What Gets Reused and What Gets Replaced

After going through the boring and honing process, the powerhead is cleaned again through a hot spray wash and pressure wash cleaning. From the machine shop, the unit gets sent to our builders to inspect each block for cleanliness and verify up-to-spec measurements. As the building process begins, each powerhead is given brand-new pistons, rings, bearings, and seals. Any other component on the unit that is out of spec is replaced entirely. By using quality parts, many made by the same suppliers as OEM, we create a truly like-new reman unit.

While using the highest quality parts is important, the way a unit is reassembled has just as much of an impact. One wrong move and the unit could fail following installation. Luckily, OBR builders are extremely experienced in powerhead assembly back to models from the 80's, meaning all OBR units adhere to the same specifications used by the OEM. Our builders are precise with inspection of parts before assembly, part placement, and machining so the unit performs - and keeps performing - exactly how it's supposed to.

Step 6: Ready for a Second Life on the Water

Powerheads are painted to black or grey specs to match their original condition, and then are sent to shipping. At shipping, they are given one final inspection to guarantee the OBR standard is being upheld. The powerhead is then boxed, padded with a foam layer to guarantee safe travel, and sent off. Just like that, the unit is ready for a second life on the water.

Why the Remanufacturing Process Matters

Full disassemblies, specialized CNC processes, cleaning, and extensive inspections give OBR the ability to provide a consistent, reliable option for customers. We know the units that leave our warehouse go through the same standardized process, which is what makes our remans so different from rebuilt units. OBR standards place emphasis on the quality and longevity of the units long after they leave the warehouse. WE are proud to be able to provide an affordable option for boaters that may not be able to, or want to, pay OEM priced; beyond that, our processgives a new life to OEM components that would otherwise end up in landfills. Our two-year warranty is in place because we stand behind our product; and with a longer warranty period, our dealers and service centers can know confidently that they're installing a quality product.

So, How Are Powerheads Remanufactured at OBR?

TLDR: OBR remanufactures powerheads through a multi-step process that includes complete disassembly, cleaning, inspection, machining, component replacement, precision reassembly, and cosmetic refurbishing. Each stage is designed to ensure the finished powerhead meets OBR's established remanufacturing standards before it leaves our facility. Need a powerhead? Contact us today or learn more about the process here.