2009 220 OUTRAGE Garboard Drain Repair

[Jcomeau0]

Q1: why is garboard drain plug on the transom of my 2009 220 OUTRAGE able to be threaded completely into and through the drain tube?

Q2; why is the drain plug on the transom of my 2009 220 OUTRAGE made of brass instead of MARELON?

Q3: what sealant should be used to bed-in a replacement garboard drain on my 2009 220 OUTRAGE?

Q4: what special tools and special methods should be used to install a new drain?

BACKSTORY
I have a 2009 220 OUTRAGE which I bought in 2025. The hull has a brass garboard drain "flange" and a and threaded brass plug for draining water from the sump. To be clear, this is not an engine splash well drain.

During Spring 2026 commissioning, I removed the threaded plug in order to apply marine grease so it wouldn’t seize up in saltwater. To my surprise, while the plug was being threaded back into the drain, it was able to be screwed all the way through the drain hole. There wasn’t a flange to stop it, nor is there a rubber gasket.

After working a while in reverse to catch the threads and get it out, I was successful. I found that a previous owner must have had a similar problem because I observed the drain passage was filled with a three-inch-long silicone caulk [plug] that has a 0.125-inch hole drilled through it allow water to drain. I’m guessing this caulking is what kept the plug from screwing into the drain passage all the way.

Looking at the parts diagram for the 2009 220 OUTRAGE, I see there’s a male tube installed from inside the transom, a female tube installed from outside the transom, and there is a removable threaded plug. It looks like these parts are made with MARELON [a plastic polymer], not from brass.

[jimh]

Q1: why is garboard drain plug on the transom of my 2009 220 OUTRAGE able to be threaded completely into and through the drain tube?

Q2; why is the drain plug on the transom of my 2009 220 OUTRAGE made of brass instead of MARELON?

My best guess is a previous owned performed a do-it-yourself jerry-rigged repair.

Looking at the parts diagram for the 2009 220 OUTRAGE, I see there’s a male tube installed from inside the transom, a female tube installed from outside the transom, and there is a removable threaded plug.

Q5: among the 38 drawings available from Boston Whaler for a 2009 220 OUTRAGE, are your making reference to the Boston Whaler drawing available at the URL linked below?

DWG 06101
THRU-HULLS
https://www.bostonwhaler.com/content/da ... s-2009.pdf

If that is the drawing, I believe you are asking about the two-part through-hull drain indicated by CALLOUT 4 and CALLOUT 8 in the drawing, and the associated plug is designated as CALLOUT 6.

The Boston Whaler part numbers are

CALLOUT 4 THRU-HULL, MARELON BW-06 SHORT FEMALE 1806032
CALLOUT 8 THRU-HULL, MARELON BW-06 LONG MALE 1806030
CALLOUT 6 PLUG, MARELON BW-06 DRAIN 1" W/GASKET 1806033

A good source for OEM Boston Whaler repair parts is from Sue Lodel. Contact information for Sue Lodel is given at

Latest Sue Lodel Contact Information
https://continuouswave.com/forum/viewto ... 551#p46706

Another source for OEM parts is NAUSET MARINE. Contact information for NAUSET MARINE is given at

Nauset Marine Contact Information
https://continuouswave.com/forum/viewto ... f=4&t=8191

Q3: what sealant should be used to bed-in a replacement garboard drain on my 2009 220 OUTRAGE?

Q4: what special tools and special methods should be used to install a new drain?

For advice on installation of a replacement two-part through-hull drain, see the youTube presentation from Boston Whaler at

Replacing a Thru-Hull
https://youtu.be/Zby76eoKO-I?t=11

I realize that the demonstration in the youTube presentation is for a scupper drain, but it should be useful for replacement of the garboard drain on your boat. Note that the presentation recommends having an authorized dealer perform the repair.

ASIDE
The topic of leaking or broken transom through-hull drains on many models of Boston Whaler boats in the c.2005 era was the topic of an archived discussion, available at

2004 220 DAUNTLESS Leaking Drains
https://continuouswave.com/forum/viewtopic.php?t=712

[jimh]

Q1: why is garboard drain plug on the transom of my 2009 220 OUTRAGE able to be threaded completely into and through the drain tube?

Q2; why is the drain plug on the transom of my 2009 220 OUTRAGE made of brass instead of MARELON?

My best guess is a previous owned performed a do-it-yourself jerry-rigged repair.

[Jcomeau0]

JimH Thanks for all of your replys. I was thinking the same thing that a previous owner did this work themselves. I’ve already contacted Sue. Waiting to hear back from her. She’s great! I’ve ordered many parts from her for my last few boats. The video was helpful.

[jimh]

Also, on choosing a sealant, I DO NOT recommend using 3M5200 or 3M4200. Those products are very strong adhesives. Use a suitable marine sealant, not an adhesive, as otherwise you might never get a second chance to replace the MARELON fitting again.

The "special tools" appear to be two "wrenches" that are designed to fit into notches in the outer face of the through-hull fittings. I bet Boston Whaler made the tools themselves.

Here is an on-line source for the two pieces of the drain tube and for the proper plug:

Part 1806030 Male tube $19
https://ebfmarine.com/products/boston-w ... 4124881998

Part 1806032 Female tube $19
https://ebfmarine.com/products/boston-w ... 4151653454

Part 180603 plug fitting $15
https://ebfmarine.com/products/boston-w ... drain-plug

The vendor mentioned above appears to be stocking a lot of useful Boston Whaler parts. See

https://ebfmarine.com/

They also have a nice archive of Boston Whaler drawings. See

https://ebfmarine.com/pages/resources

[Jcomeau0]

JimH thanks again. I actually went and ordered those from that source after posting my earlier response. Wanted to get them ordered asap. I’m probably going to use [BoatLife Caulk or BoatLife Sealant]. I still have to do a little research but I used one or the other on my transducer screw holes as well.

On a side note, after watching the [youTube presentation linked above showing through hull replacement] , I removed the fittings from the transom. I didn’t have the proper spanner wrench so I used a pair of needle nose pliers. The fittings came out surprisingly easy.

I will fabricate some type of wrench to install the new fittings because I don’t want to ruin the Marelon surface--but I want the fittings to be tight.

The existing fittings were Marelon with the exception of the brass plug. The female threads had brass stains from the plug. I’m guessing the brass plug [was mis-threaded and damaged] the plastic threads, and that’s why [the drain on my boat] no longer had a good seal.

[jimh]

I am glad you found my comments useful. When you complete the replacement of the two-piece MARLON through-hull fittings, let readers know about any problems you encountered and solved in the process.