496 exhaust on a 502 mpi
 

I am putting 496 exhaust on my 502 and I am under the impression that i will have to relocate some things and/or build new brackets. I was curious if anyone had any pictures or tips of how to bulid the bracktes or where to relocate everything.

i mounted everything on the transom really cleaned up the motor

We have some remote oil filter mounting brackets off of stock Merc 496's that would probably allow you to remount the remote oil filter lines possibly to it and bolt it on the stock 496 exhaust manifolds.. I'll give you one just send Raylar a USPS prepaid postage box (12x8x6 or so) with your address and such all filled out on the box. Then let us know if it will work easily for this type of exhaust conversion.

Best Regards,
Ray @ Raylar

ray, it does have the oil filter bracket on it already but that is really nice of you to offer that for me.
mach1- any pics of how you mounted the stuff?

Yes, the stock 496 oil filter bracket and oil filter base are one piece and it is designed to bolt to the front two bolts on the 496 manifold to riser studs. I am not sure the existing 502 oil lines to the remote filter will fit to point were you can connect then directly to the 496 filter bracket base. You might go to Mercruiserparts.com and look up on picture search and compare the 502 and 496 engine oil filter pictures and see what you think.

Best Regards,
Ray @ Raylar

I am getting ready to do the same thing. I would be interested in any ideas you come up with. If I figure out some ways to remount things I will share them with you also. My boat has very limited room on the transom. I plan on fabricating some brackets out of aluminum to remount some items.

Im hoping I will get a chance to install this week. I polished the risers pics to follow.

i just put polished risers on mine, looks alot better, don't forget 10 hp by removing turbulators

I am planning on polishing my risers also, and possibly the manifolds. Manifolds look like alot of work to polish. I need to finish the interior of my pole barn before I start on the boat so it will probably be a couple of months before I start on my manifolds

I used the 496 oil filter bracket and managed to get the oil feed and return hoses to fit even though it was a little tricky.
Attachment 467427

Looks like the bracket will work. I would be interested in buying one from you Ray

I got mine on, I was able to use the oil bracket that was there. Now I am in the process of building brackets for ecm and shift cables. hadley I have a bracket that I will give to you if you want it, just cover the ride.

That would be great. how would you like to do it , paypal or I can mail you a check, let me know. zipcode is 48455

Hadley your pm is full. I just sent the part to you. Don't worry about shipping its not enough to mess with. Just pay it forward. Hope it works for you.

Travis

Thanks so much. Sure is alot of great guys on this website

Workin on the exhaust now. I am polishing the risers, Lot of work getting in all the tight spots. I also stripped the paint off the manifolds. They look pretty good without any polishing. I picked up used a remote filter mount off of a Merc. 420. Mounts to the back of the port head. Will need to get new oil lines made up. I cant seem to find a fitting that fits on the stock oil cooler. It is a male inverted flare. Going to mount the shift bracket to the transom. Will probably make some aluminum brackets to mount the module and electrical connectors to the manifolds. Excited to get on the water and see how much faster the boat is. Probably at least 6 mph with the new manifolds

Nice to hear your project. I would not advise getting to over excited about seeing a +6mph speed increase alone from an exhaust upgrade alone, kinda think you should be thrilled to see 2-3 mph if you are lucky enough to achieve that though.

Best Regards,
Ray @ Raylar

Thanks Ray. I was only kidding about the 6 mph. I would be happy to see any gain. I am guessing that I will be gaining about 15 horsepower, What do you think?

You're close

Best Regards,
Ray @ Raylar

Took the boat out today with the new exhaust. Gained 1 mph. Which I am happy with but I have a new problem now. I burnt a hole thru the top of the starboard exhaust hose. The 496 exhaust is about 2 to 3 inches taller than the 454 exhaust which was not a problem for the stock rubber hose to bend that far. Apparently it was to much of a bend to not burn thru. Still trying to figure out a solution to this problem without spending another $500 on silicone hose or custom adapters. I may cut and weld some aluminum tubing to compensate for the offset.

I just picked up a set of Aluminium 496HO Manifolds (single Inlet) and SS risers. They are off a 2004. I have a 99 stock 502 in a 272 baja (OEM). I have the ecm, shift & oil brackets from the 496HO. Will those brackets all bolt up or do I need to buy specific ones. Thanks.. https://cimg4.ibsrv.net/gimg/www.off...488d6fa6ff.jpg