The Buckshot Racing #77 Cowl Support Plug (part number 821881-77) is a high-performance, precision-engineered billet aluminum replacement for the now-discontinued stainless steel pipe plug originally supplied by Mercury Racing under part numbers 22-821881, 22821881 (Mercury Marine), and 821881 (Quicksilver).
This plug was a critical component in the upper cowling support system on Mercury Racing’s 2-stroke outboard engines, serving as the central threaded anchor for lightweight race cowl brackets.
Originally manufactured in stainless steel, the OEM plug featured a 1/2" NPT male thread and a central 5/16"-18 UNC threaded hole approximately 1 inch deep. This allowed for a secure bolt connection to the cowl support bracket and ensured both structural alignment and vibration resistance in high-performance environments.
The Buckshot Racing #77 plug preserves this exact form and functionality while introducing substantial upgrades in materials and machining.
Machined from aerospace-grade 6061-T6 billet aluminum, the #77 plug offers a significant reduction in weight compared to the original stainless part—an advantage in racing scenarios where every gram counts.
The material also delivers exceptional strength and marine-grade corrosion resistance, making it ideal for long-term use in saltwater and high-humidity environments. CNC machining ensures precise tolerances, consistent thread engagement, and a reliable seal within the cylinder block, while the uniform grain structure of billet aluminum helps prevent fatigue or stress cracking from engine vibrations.
In addition to securing the cowl support bracket, the plug also seals an important water passage at the top of the engine block. This helps prevent water ingress that could lead to internal corrosion or performance degradation—an especially important function in high-speed marine racing where reliability is critical.
The Buckshot Racing #77 plug is available in anodized red, blue, or black finishes, providing both visual customization and additional protection. The anodized surface enhances resistance to oxidation, saltwater corrosion, and thread galling—particularly valuable when mating with aluminum or stainless threads. This durability makes the plug ideal not only for current racing builds but also for preserving vintage or legacy Mercury Racing engines.
Designed to be fully compatible with original Mercury part numbers 22-821881, 22821881, and 821881, the Buckshot Racing #77 plug fits a wide range of legendary 2-stroke outboards, including the 2.0-liter SST-120, European XR2, and S2000; as well as the 2.5-liter 245 HP Carb, 260 EFI, 280 ROS, 300 Drag, and S3000 models.
It also supports adapted Mercury CC, EE, FF 200HP, and Pro Max NN 225HP outboard drag racing builds in various competition formats. It maintains compatibility with dedicated Formula One and F1H2O racing engines, where lightweight durability and precision alignment are essential.
Whether maintaining a vintage tunnel hull, building a lightweight 2.5L powerhead, or competing in international Formula racing circuits, the Buckshot Racing #77 billet cowl support plug delivers a superior modern solution. By combining performance-focused materials, advanced machining, and full OEM compatibility, this plug supports the continued performance, longevity, and reliability of Mercury Racing’s most iconic outboard platforms, long after factory parts have been discontinued.
For technical support, contact Mike Hill at mike@buckshotracing77.com or call +1-714-697-1716