Canadian Plastics

Groundbreaking outboard engine parts rely on reinforced nylons

Rugged, beautifully finished cowling components for Mercury Marine's revolutionary Verado outboard boat engine swept the annual Product Design Competition sponsored by The Society of the Plastics Industry's Structural Plastics Division in March, c...

May 1, 2004   Canadian Plastics



Rugged, beautifully finished cowling components for Mercury Marine’s revolutionary Verado outboard boat engine swept the annual Product Design Competition sponsored by The Society of the Plastics Industry’s Structural Plastics Division in March, capturing four awards for innovation and groundbreaking design. The cowl consists of six parts injection molded from DuPont high-performance plastics by Bemis Manufacturing Co.

The cowl fulfills structural, protective and aesthetic functions while reducing weight and cost compared with Mercury’s alternative materials.

The top cowl is believed to be the largest component ever injection molded from glass-reinforced nylon. Made of a 33% glass reinforced DuPont Zytel nylon, it is shaped like a giant scoop measuring 851 mm (33.5 in.) front to back, 582 mm (22.9 in.) across and up to 417 mm (16.4 in.) deep. It weighs just 11.3 pounds (5.13 kg), far less than a metal or a thermoset plastic housing.

The rear cowl, and a structural rib that is adhesive-bonded to it, are molded from the same Zytel resin. The front cowl is molded from DuPont Minlon mineral/glass reinforced nylon for added flatness. The lower cowling, or chaps, consists of two mating parts molded from DuPont Surlyn Reflection Series supergloss alloy for superior gloss without paint.

These components meet several demanding requirements:

They mate precisely to prevent water from entering the engine compartment.

They provide improved noise/vibration/harshness properties, making Verado the quietest, lowest vibration engine in its class

They provide structural strength and impact resistance.

Stand up to temperatures up to 200F in the upper cowl.

The cowl parts made of Zytel and Minlon nylon resins are finished in a three-coat system providing first-pass acceptance yields of 95% or better at each stage, according to Mercury Marine.

The lower cowl molded from DuPont Surlyn Reflection Series supergloss alloy has high-gloss finish and integral color. It incurs no painting costs.

DuPont Canada Inc. 905-821-5953


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