Help - Can't get the electrical box open

[EvanB85]

I can't get the e-box open on my sj. The mounting brackets that cover the last two screws will NOT budge. I can't totally tell, but it almost looks like the mounting bolts have been epoxied. I'm tempted to cut the brackets to get to the screws, but that doesn't solve the frozen bolt problem. Suggestions?

 

[SuperJETT]

What mounting brackets?

Take 2 nuts off to pull box off the brackets that are on the hull, remove the 100 or so screws to pull the front cover off, reverse.

 

[WaveDemon]

I can't get the e-box open on my sj. The mounting brackets that cover the last two screws will NOT budge. I can't totally tell, but it almost looks like the mounting bolts have been epoxied. I'm tempted to cut the brackets to get to the screws, but that doesn't solve the frozen bolt problem. Suggestions?

I had real bad corrosion there once. you can unbolt the 4 bolts on the tray side of the fire wall to get it out and work on your frozen ones once it's out.

 

[EvanB85]

JETT, I understand what you're saying, but I went ahead and unbolted the whole thing from the outside. I could re-mount it to the dash, but if I start pulling I think I'll rip those bolts right through the glass. That box does not want to come off the bracket.

 

[Shonuff]

Let's see some pics.

 

[SuperJETT]

Ok, gotcha. I've never had a problem with those bolts so just couldn't picture some other brackets that I may not have and you would.

 

[EvanB85]

Take a look at this for reference. The mounting bracket (part 36 in this diagram) will not budge. I can't get to the last two screws with the bracket still on there.

 

[WaveDemon]

you are saying the nuts (part #38) are stuck right? can't you unbolt bolt #37 from the tray side and take out the box and bracket together?

 

[vomitspot]

if its stuck really bad and you have the nuts off take a hammer and tap the brackets like unscrewing them untill you have access to the screws or unscrew them all the way and clean out the corrosion
lastly clean your ski so this will not happen again
jason

 

[EvanB85]

WaveDemon, I've already pulled it from the dash with the brackets still on the box. I can't open the box until those brackets come off though.

Vomit, brute force is the next option indeed. I've only had the ski for a year and this is the first time I've tried to open the e-box. It was a stocker when I bought it too, so I'ts probably never been opened in 14 years. I keep the the thing pretty clean though, and I was not counting on finding that much corrosion at a metal to plastic connection.

 

[felix5oh]

it will come off. Sounds like corrosion on the stainless bolt. Tap on it, like they said.

 

[wayne]

get a pry bad and put it over the end of the ratchet that way you have a longer ratchet handle.

remember the old saying:

If it don't move, force it. If it breaks it needed replacing anyway.

or

If it don't move, get a bigger hammer.

 

[vomitspot]

the base of the box is alum. not plastic that is where the corr. is
gently tap on the bracket it will move.
go counter clockwise it might unscrew all the way then you can clean out the corrosion with a file it drill bit
good luck
hurry up datona is just around the bend
jason

 

[Boris]

I encountered a similar problem on a friends ski.

Bend the two brackets out of the way and unscrew the last two machine screws (phillips head), do what you have to do in the e-box and screw the cover back on.
Last step, bend the two brackets back in place and bolt up the the fire wall.

Worked like a charm and nothing broke.

 

[EvanB85]

I encountered a similar problem on a friends ski.

Bend the two brackets out of the way and unscrew the last two machine screws (phillips head), do what you have to do in the e-box and screw the cover back on.
Last step, bend the two brackets back in place and bolt up the the fire wall.

Worked like a charm and nothing broke.

I thought about that, but was a little sketch on putting that much stress on the box. That would do the trick though. I guess I'll give it a shot.

Vomit, the base of the box is aluminum? I'll take your word for it. Does explain the corrosion though. As far as Daytona goes, no worries. That's a 6,258 mi round-trip for me. Anyone who makes it from WA gets a medal from me. Besides, SuperJETT is setting up a webcam - what more could I need?

 

[EvanB85]

get a pry bad and put it over the end of the ratchet that way you have a longer ratchet handle.

remember the old saying:

If it don't move, force it. If it breaks it needed replacing anyway.

or

If it don't move, get a bigger hammer.

There is no hex head on that bolt, its flat and round.

 

[WaveDemon]

WaveDemon, I've already pulled it from the dash with the brackets still on the box. I can't open the box until those brackets come off though.

Vomit, brute force is the next option indeed. I've only had the ski for a year and this is the first time I've tried to open the e-box. It was a stocker when I bought it too, so I'ts probably never been opened in 14 years. I keep the the thing pretty clean though, and I was not counting on finding that much corrosion at a metal to plastic connection.

I've had that problem. it's corrosion, I used a BFH and between beatings I would try to twist it with vice grips.

 

[EvanB85]

Demon, what kind of BFH do you use? Craftsman? Snap-On?

 

[WaveDemon]

Demon, what kind of BFH do you use? Craftsman? Snap-On?

I don't know, it kinda looks like this:

 

[RoyalFlush@PCB]

I don't know, it kinda looks like this:

:haha: