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-   -   Gen 5 header clearance issues? (https://www.offshoreonly.com/forums/do-yourself-boating-budget/297981-gen-5-header-clearance-issues.html)

xlint89 09-08-2025 09:16 PM


Originally Posted by PQ290Enticer (Post 4934349)
Just to get through this boating season you might be able to use a silicone hose to connect them. Much more pliable. Might have to cut another inch of of the exhaust tip to make it work? Other than that, I would go with modifying the exhaust tips. Going to have to "Pie Cut" till they line up.

Realistically. this season is not happening.Stuff is just taking much longer than I had anticipated. And every time I do something, I find something else that needs something ordered/bought.


Originally Posted by Mbam (Post 4934359)
Find someone to modify your tips with a S bend (double miter). Looks like there is room. Might have to massage the transom opening on the inside to get them in.

Thanks for the suggestion. I'll have to try and find someone who can do that type of work. Thanks

xlint89 12-08-2025 07:49 PM

Well, I managed to find these.

https://hpsperformanceproducts.com/p...44244868464892

Not too sure if they'll work, but might help someone else.

I'm going to send them an E mail and see if they can make a set in the higher temp silicone. (500* as opposed to the 350*)

xlint89 12-14-2025 03:14 PM

Heard back from HPS. They say as long as water flows through the exhaust, the 350* coupler will work fine. Was hoping to have a higher margin for error with the 500* material.

Only have the offset coupler in 1/2".

To have a custom piece made would require a minimum of 50 units.

halfgassed 12-18-2025 07:01 AM

https://cimg0.ibsrv.net/gimg/www.off...e41d4b302.jpeg

halfgassed 12-18-2025 07:04 AM

https://cimg5.ibsrv.net/gimg/www.off...328d553c9.jpeg

halfgassed 12-18-2025 07:21 AM

I feel your pain! I guess I probably should have updated this post.

I fought with the fitment of these headers in my boat, even to the point CMI took pics for their R&D guys. They were very helpful all the way through, some were my fault…some were theirs. In their defense mine were some of the first few sets on the market. I’ve noticed since they have changed the distribution tubes on the front 2 cylinders from being straight down to angled toward the transom….

I took my alternator bracket off an “extended the radius” for the belt adjustment, so I could swing the alternator closer to the engine block and just run shorter belts, that definitely helped. I used a mill but, A steady hand, a die grinder and a chainsaw file would work too. I have the 90 degree rubber distribution tube to headers as well. If i remember right I did have to have one of distribution tubes flipped 180 as well.

Above is pics of the offset plates to cover the transom holes I had made, I used a wire edm to make’em but pretty sure anyone with a cnc plasma table could burn’em out for you. Not to mention places like send cut send.com would does plasma/laser cutting etc could do it as well.

halfgassed 12-18-2025 07:24 AM

Just curious was all you changed was just going to different cylinder heads?

JaniH 12-18-2025 07:41 AM


Originally Posted by CheckmateScarab (Post 4932495)
I have a high output alt, power Master 8500 marine, and had to use this bracket to clear the manifold, might work for your case too
https://cimg2.ibsrv.net/gimg/www.off...a35bc190a6.jpg
its still very close but helps the clearance. Power steering pump gets pushed up substantially higher, though

Do you Have partnumber For this bracket? This might help me with stelling green headers.

xlint89 12-18-2025 08:20 PM


Originally Posted by halfgassed (Post 4940267)


Originally Posted by halfgassed (Post 4940268)

It was because of your post I ended up making a set of beauty rings like yours. Thank you for that.

I wound up buying a 1/16" stainless steel kick plate for a commercial door, and carefully cut the rings with an angle grinder out of it.

I'm hoping to not use them as that would mean I had cut more material from my transom. I'd like to find a better alternative if possible.

I did see Corsa will make custom tips and some of theirs do have offsets like I need. Will prob be around $450-500 though.


Originally Posted by halfgassed (Post 4940271)
I feel your pain! I guess I probably should have updated this post.

I fought with the fitment of these headers in my boat, even to the point CMI took pics for their R&D guys. They were very helpful all the way through, some were my fault…some were theirs. In their defense mine were some of the first few sets on the market. I’ve noticed since they have changed the distribution tubes on the front 2 cylinders from being straight down to angled toward the transom….

I took my alternator bracket off an “extended the radius” for the belt adjustment, so I could swing the alternator closer to the engine block and just run shorter belts, that definitely helped. I used a mill but, A steady hand, a die grinder and a chainsaw file would work too. I have the 90 degree rubber distribution tube to headers as well. If i remember right I did have to have one of distribution tubes flipped 180 as well.

Above is pics of the offset plates to cover the transom holes I had made, I used a wire edm to make’em but pretty sure anyone with a cnc plasma table could burn’em out for you. Not to mention places like send cut send.com would does plasma/laser cutting etc could do it as well.

If you have any good pictures of your set up, could you please post them up? I'd love to see what you came up with.


Originally Posted by halfgassed (Post 4940272)
Just curious was all you changed was just going to different cylinder heads?

No. There were many things changed, but the cyl heads I would have thought would be the only thing that changed the exhaust height?

Went from OEM rubber engine mounts, to solid billet mounts. These are nearly maxxed out, but the out drive dictates where the engine has to be. SO that couldn't have changed height. Right?

Brand new engine block. Gen V or VI with a fuel pump mount on the block. Not sure if engine mount locations changed? I can't believe they would. That would cause chaos for anyone buying the block to replace an old one.

xlint89 12-18-2025 08:22 PM


Originally Posted by JaniH (Post 4940273)
Do you Have partnumber For this bracket? This might help me with stelling green headers.

Here you go.

https://www.cpperformance.com/p-1388...g-bracket.aspx


And here's more that might help you out.

https://www.cpperformance.com/vsearc...ator%20bracket


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