Mercury Outboard Throttle Lever

STL files for this project are available at Printables.com and can be found HERE.

This project is a temporary replacement Lever Throttle for an outboard motor. (Mercury Part# 44425)  I went to take my boat out and noticed I didn’t have any throttle.  A quick inspection and I found that the throttle arm had cracked and was just spinning on the throttle shaft.  Apparently this is a common part to break and it almost ruined a day of fishing for me… that is if I didn’t have a 3D printer.

I jumped on the computer and quickly designed a replacement piece in Solidworks.  I tried to beef it up a bit from the original one and I used a 6mm x 35mm? (give or take a few mm’s?) bolt I had laying around as the post so it would stronger than trying to print that part. (I did tap the hole in the print prior to inserting the screw.)

I printed this in ABS at 90% infill and a half hour later the day was saved and I was ready to go fishing…. another testament to owning a 3D printer.

It’s probably stronger than the original but I only plan on using it temporarily until I get the replacement but so far it’s worked perfect and will be worth keeping in the boat as a extra. (If I were to use it for longer periods of time I’d probably put a sleeve over the screw threads to avoid wear of the mating throttle linkage.)

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