I posted a response to Cubfan's question on the RC Groups forum, but here it is again for the rest of you:
Can you describe WHERE the cables are breaking?
If I may venture a guess, I'd say they are breaking either very near the stub shaft (within 1/4" or so of the stub shaft, just up from the flats??) or very near the coupler??
On the
https://forums.offshoreelectrics.com/forum.php forum, I have a "race prep" thread for this boat where I describe some prep work I did on my lower units to increase their reliability and reduce maintenance, as well as reduce drag.
Here is a link to that thread:
https://forums.offshoreelectrics.com/...etto-Race-Prep
One think I noticed is that the holes in the cases of the lower unit that are at either end of the channel that holds the teflon stuffing tube are a little bit on the small side. I disassembled my lower unit to get all the internals out and to clean up the halves (there can be bead-blasting debris in the cases from the manufacturing process). Putting just the two halves together, I opened up the holes where the flex exits into the prop-shaft and at the top near the coupler to provide a little more "wiggle-room" for the flex cable in these areas. I also used this opportunity to assemble the motor, stuffing tube, prop-shaft, coupler, and flex shaft onto one-half of the lower unit so I could assure that the coupler is installed to allow the proper flex-shaft end-play and wasn't binding. There should be a slight amount of end clearance of the flex in the coupler and the prop-shaft.
What I suspect is happening with your flex cables is that they are either binding from being jammed down with no end-clearance in your coupler/prop-shaft, or that they are rubbing on the holes I described above.
All that being said, I have been using Lawless or K&B stubs in mine, simply because that's what I have, and also because they tend to have JUST ENOUGH flat at the ends (the flats aren't overly long), so the cable can bend a little bit more toward the ends.
Hope this helps.
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