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Jet Ski Exhaust Manifold Repair

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  • Jet Ski Exhaust Manifold Repair

    The exhaust manifold on my customers 1996 personal water craft (Jet Ski) was a sand casting that had two concentric tubes; an inner tube and an outer tube. The exhaust goes through the center tube and lake water goes between the two tubes. There were two holes on each side of the manifold that which I assume were used to remove the core sand from between the two tubes of the casting during manufacturing. The four holes were blocked off with caps that were welded on during manufacturing. Over time the water corroded the caps so that there were eventually two pin holes in one of the caps. My customer carefully cut off all four corroded caps and made new ones. I enlarged the holes to remove the oxidized material on the ID of the hole, because I was concerned that the contaminated material would get sucked up into the weld and contaminate it. Then I welded the four caps in place. I am guessing the a new manifold would have been pricy.

    Don
    Attached Files
    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport
    Miller Spectrum 375 Plasma Torch

  • #2
    Looks like a good repair, Don.<br />
    <br />
    Is that a foredom flex shaft you're using there to burr that material out?

    Comment


    • #3
      Originally posted by ryanjones2150 View Post
      Looks like a good repair, Don
      Is that a foredom flex shaft you're using there to burr that material out?
      Yes it is a Foredom flex shaft grinder.
      I am surprised that you could identify it when looking as such a small part of it.
      I really like them for fine work.
      I have a ton of carbide burrs and other accessories for it.

      Don

      Miller Thunderbolt
      Smith Oxyacetylene Torch
      Miller Dynasty 200DX
      Lincoln SP-250 MIG Welder
      Clausing/Coldchester 15" Lathe
      16" DuAll Saw
      15" Drill Press
      7" x 9" Swivel Head Horizontal Band Saw
      20 Ton Arbor Press
      Bridgeport
      Miller Spectrum 375 Plasma Torch

      Comment


      • #4
        I have a couple myself. Great tools, handy too.

        Comment


        • #5
          Originally posted by ryanjones2150 View Post
          I have a couple myself. Great tools, handy too.
          My customer sent me a picture of the original manifold with some pin punches poking through the holes in the caps of the Exhaust Manifold, before he ground the caps off. Two of the holes went all the way though one cap.

          Don
          Attached Files
          Last edited by Don52; 07-22-2016, 08:27 PM.
          Miller Thunderbolt
          Smith Oxyacetylene Torch
          Miller Dynasty 200DX
          Lincoln SP-250 MIG Welder
          Clausing/Coldchester 15" Lathe
          16" DuAll Saw
          15" Drill Press
          7" x 9" Swivel Head Horizontal Band Saw
          20 Ton Arbor Press
          Bridgeport
          Miller Spectrum 375 Plasma Torch

          Comment


          • #6
            maybe you should've welded it better, Don.

            Comment


            • #7
              Originally posted by ryanjones2150 View Post
              maybe you should've welded it better, Don.
              I think that was before it was fixed...Bob
              Bob Wright

              Spool Gun conversion. How To Do It. Below.
              http://www.millerwelds.com/resources...php?albumid=48

              Comment


              • #8
                I figured that Bob, cmon...my sarcasm escaped you?

                Comment

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