Major Problems !!! Merc 525 Internal Flappers
 

I am having to send back for repair Stainless Marine's exhaust tips with their internal Sainless Steel Super Flaps approximately every 27.86 hours. The flaps themselves beat the rubber off the elipitical edges. Then they proceed to further self distruct by beating all of the rubber off the flapper while continuing to to wear the stainless steel to a round shape. Has anyone out there had problems with internal flappers on 05 Merc 525's ? Is it correct that Merc reccomends internal flappers on 525's because of reversion? Any solutions would certainly be appreciated.

Thanks,
Boyce

I´ve got 160 hours on my 2006 525 fitted with Eddiemarine tips with internal flappers. No problems whatsoever. The flappers make a noise at idle but quieten down at about 1200 rpm. The rubber is still on them and they look fine. Maybe you shouldn´t stay in the no-wake zone the whole day!:hitfan:
The flappers don´t really have anything to do with the reversion issue. The water that is in danger of reverting is coming from in front of the flappers (cooling water) anyway.

I've got GGB Extreme's with internal rubber flappers and I just replace them when they get frayed on the ends. I got about 60 hours out of the first set.
I would not run any tips without flappers to help stop reversion from wave action agains the stern.

I had an 04 with 525's and had to replace the same flapper twice. It was a Rex Marine product. The other three flappers with 200 hours were fine. I talked to Rex Marine and they could not figure out why the flapper failed.

I'm on my third set of EM flappers. Damn things won't stay in!

Internal Flapper Problems
 

Kennyo,I had an initial problem with the whole flapper unit being blown out and Stainless Marine increased the pin size and that solved that problem. However, the silicon rubber is coming off now.
Have you or anyone else had problems with the high temp rubber? Mine are going out in about 27 hours.

I had that problem and put some Rex Super flappers on the 27ZX. I then sold it. They worked well but I got busy and did not have time to switch them out first. My 26 that is getting an Eddie engine has the EM's. How long do you think they will stay in with 800+hp?

Internal Flappers
 

Stainless Marine says that the 525's are more of a problem than the higher horse power engines.