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Tubs, perhaps my ball OD is a little undersize, but it slips into
the new pad with no problem. Of course the new pad’s ears
have never been cinched down, so perhaps it’s a different
story re-installing a used pad.
Anyhoo, here’s what I did with the screw and pad today.
I made a little sleeve for a mold, and put two 1/2″ nuts
below it, to force the mold off after alumi-brazing.

The mold on the transom screw, ready for action.

Removing the mold with the nuts…. that worked slick.
I ground the excess brazing off the top of the mold on
the belt sander first though.

If I were to do it again, I would play the torch around the mold
a little bit after the mold was filled with braze, as I ended up
with a little void around the center perimeter. Don’t think
it’s going to matter much.
I finished it off by shaping the ball on the belt sander, little by
little, test fitting it in the pad. I also did a little deburring and
enlarging in the bottom of the pad’s socket with a Dremmel,
as Art said might be necessary.
Maybe I’ll try installing it back on the motor tomorrow.

Prepare to be boarded!