Originally Posted by Vinny P (Post 2761749)

Are they original from Mercury? If so, what year are your engines? We looked at replacements, as you said, Weiand makes a direct replacement. The concern is they are aluminum and will corrode faster than the cast iron ones did. I called a company in Connecticut, who I use to ceramic coat things. I have had them do a few intake manifolds for me in the past. Mostly, I had the coating put on for asthetics. Anyway, they claimed they have ceramic coated aluminum intake water crossovers, strictly for corrosion protection. They claim the process yields successful results. In case the intakes are deemed unrepairable, we may go for new Weiand aluminums and have them coated.

Anyone ever try this?

Originally Posted by Vinny P (Post 2762242)

JayTee,

I didnt do the magnet test. The manifolds are too heavy to be aluminum. When I cleaned the gasket surfaces with my air operated cookie cutter, I would have noticed it taking off metal. The gaskets were the only things coming off.
The machine shop who is doing the welding and milling said they are not cast iron, but an alloy of some sort. John talked directly to them, I am not sure of exactly what was said. My hope is that they can weld them. Sure felt like cast iron to me.

Originally Posted by ciaoderhead (Post 2763798)

The ones on my 2002 575's are aluminum. They apear to be hard coat anodized. I just welded them up with 6061 rods and checking into having re-hardcoated. They only needed welding at the rear of the manifold at the water passages.

Originally Posted by oklaoutlaw (Post 2764099)

So where was the problem? I just got mine and they have about 250 hrs of mostly Saltwater use. Should I be checking something? What kind of hours do yours have?