Griff

First of all does anybody have a Merc 525SC intake they want to sell????
Mine is pretty corroded around the front water jackets.
I really don't want to go to a regular Weiand 177 Intake. The T-stat mount is on the opposite acccording to the pic I found and that won't work with a Merc T-stat housing.

It's really only corroded badly around the edge of the 2 water jackets. I suspect the salt water it was in for a while got behind the gasket there and started eating away. There is not enough metal left to get a gasket to seal, or at least its too close to take the chance.

Any other options???

Maybe grind it down to good aluminum and get it welded????

Whitey

Griff,
If you can get it cleaned well you can use JB weld and fill it and form it to the shape you need.
I know of the epoxy being used for this type of repair and have not heard of any problems with it. Dwight

Griff

I thought of that. The problem is that to get it cleaned up enough, I would more than likely have to grid all the mating surface off at the top of the jacket in the pic. Thus when it gets torqued down, it could crack off and I'd never know it till my oil turned into a milky mess.

Whitey

If you are shy about that then I am sure it culd be welded. Then you do not have to worry. You may need to have it machined flat after welding depending how the welding is done. D