Gen 5 header clearance issues?
 

heres a little back ground...1990 fountain 38 fever. Carbed gen 5, 454 mags with bravo drives. I am in the process of replacing my center rise manifolds with CMI's 454/502 bravo headers.

heres a link to the headers....
Teague Custom Marine 454/502 E-Top Platinum kit - Elbow Top Headers 454/502 496 Mag Small Block - SS Header Exhaust Systems - Exhaust Systems - EXHAUST

I'd like to see if any one else has run into any of these issues and how you remedied them. Heres some of the issues I've run into so far, and how I've solved some of them.

My biggest unsolved is now my alternator will not clear the water inlet tube into the one header tube, I can't even squeeze the hose in between the alt/and the tube thats welded on the header. Its a mando alternator and in my research I cant seem to get a smaller case alternator than what I have, at least in a marine app. The 1 wire off my plow truck clears it just fine. The stupid cover for the external regulator on the mando is the big issue.

next issue- oil lines, I cant seem to get any new longer oil filter relocation lines made here intown, I'm tempted to by the tools to do all my own AN lines, the factory merc lines were too short for the CMI relocation brackets.

next-Exhaust tips needed to be moved up 1.125". I Cut the existing holes up and reshaped them, and then machined some nice stainless "ovals" with an offset 4" hole for the tips to go through.

next- trying to mate them up to the factory merc silent choice. It wouldnt have been an issue until I had to move the exhaust tips up. The merc rubber bellow for the oval shape of the Y pipe and the silent choice is not a standard 4, or 3.5" exhaust hose. It needs to be 3.75 diameter. Which wouldnt be a problem if the factory merc oval shaped hose could be had in a longer length......but theres only one length available........and in my app thats too short, so I had to track down some 3.75" hose.

Thanks
Matt

Sorry for the dead thread resurrection.

This is exactly the same issues I'm having right now.

Installed Promaxx heads on the HP 500 carb engine and the exhaust tips are about 7/8" lower then the CMI Fusion pipes. I do not have access to a machine shop to make my own beauty rings to cover the longer holes.

Does anyone think I can utilize one of these 7" OD x 5 1/" ID transom rings from Hardin if I trim my exhaust tip OD to fit inside it? https://www.cpperformance.com/p-1105...ange-each.aspx

The Mando alt is only 55 amp and is small in case size. It already has an issue with the water supply hose connection to the header. If I were to try and use my high output alt, the case is wider and it stands no chance of fitting. I'm looking at possibly altering the water supply hose to feed the pipes from the back side instead of the front. (just spin the water supply manifold 180*) Not really ideal as it will possibly rest on the headers.

If anybody has any suggestions, I'm all ears. Thank you

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

I would have a welder modify your exhaust tips or have Teague make a set

Thanks for the reply. I was looking into those, but no pictures of them installed means I have no idea if it would work for me?

I may have found a possible solution. I sourced a set of those stainless distribution tubes and can possibly use rubber 90* elbows to feed the pipes water. This pushes the hoses away from the alt.

I appreciate the response. Modify them how?

The fusion headers are now positioned 7/8" higher than the exhaust tips. Thank you

https://cimg6.ibsrv.net/gimg/www.off...1334e3b87e.jpg
https://cimg8.ibsrv.net/gimg/www.off...26391bf7d5.jpg
https://cimg1.ibsrv.net/gimg/www.off...40669e1ce8.jpg
https://cimg8.ibsrv.net/gimg/www.off...8e187d0028.jpg
I ordered some "L" hoses to use with the cooling feed. Hopefully this will get around my clearance issue with the aftermarket alternator and CMI headers.

Unfortunately I'm still kind of stuck with the exhaust height problem. I can't raise the exhaust tips too much because the flange is really close to the bottom of my swim platform. And I'm not crazy about cutting the holes in the transom much bigger. You can see I did it once already when I had the Seaward exhaust installed and the height was a little bit off then.

Does anyone think I can use the transom rings with the silicone seal and new tips at a slight angle? https://www.cpperformance.com/p-1370...x-4-12-id.aspx Or these? https://www.cpperformance.com/p-1105...flap-each.aspx

Or does anyone have another idea? Thank you

Would the 12* angle mounted tip work?

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.

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.