I'm just not convinced that any of the long tube headers out there are better. If you don't use a long tube header with this engine you will lose power. My pockets aren't especially deep right now but I'm going to take my chances with the CMIs. I have read all of the reports but there are an awful lot of 525s out there. The problem also seems to be more prevalent on big twins with long, unsupported tails. Now I just hope I didn't jinx myself .

See post #44 on page five of this thread. I USED to think the same way you do about my old headers.... "It CAN'T happen to me, my boat is FRESH WATER use only, it has LOW HOURS and is NON-STAGGERED!"

Also, there are a lot more of these header failures going on out there then we are being made aware of here on OSO. Last Summer when I HAD to replace mine, Hardin Marine had their replacement headers on back-order for at least a month. When I talked to a Hardin Marine rep at the Miami Boat Show in February, he said that they were STILL having a hard time keeping up with demand... What does that tell you?!

I'm not trying to scare anyone, but unfortunately, what SHOULDN'T be considered "routine" maintenance (IMO) now IS for anyone with these POS Mercury Racing/CMI Headers.

For further information as to what happens when these POS Headers fail, see post #31 on page four of this thread... as bad as I felt about MY situation, Mykalvballer's was FAR worse!

Then the only question becomes: How lucky do you feel???

well said perfect storm! even the wealthiest performance boater wouldn't throw that kind of cash away

SippyRat, I'm looking forward to seeing your new headers installed. I'm not denying the problems but what if there was a thread where people who have not had any header problems with a 525 could post up. I supposedly have the newer style headers with the exposed collar. I put on silicone hose so there won't be much stress from vibration and engine movement and I guess I'll hope for the best.

well i received my 2nd set and yes they are new and so far appear to be in great shape. only missing the tailpipe gaskets and bolts this time around. hardin apologized once again and is overnighting the parts to me. looks like they have some work to do if they want to prevent these types of experiences in the future. THE CEO NEEDS TO CRACK THE WHIP or eliminate the bad apples from ALL parties involved!!!! too many deals like mine can bring a company down in a heartbeat. hopefully with any luck i will have everything i need to make the swap this weekend............

I installed my Hardin Hurricane Lite Headers today. The install went pretty smooth once Scott from Hardin got me everything i needed. Thanks again Scott and everyone at Hardin for the way you handled this somewhat stressful transaction. I do however have one problem. My engine has the round power steering reservoir which will need to be relocated. The header is could not be installed until I removed the reservoir and mount bracket. I am at a loss at what to do here. Scott I know you said this wouldn't be the case but it is. Do you have a different bracket or a solution for me? Has anyone else had to relocate the reservoir??

you can see in this pic i just have it propped up with the mount bracket:








this one is more of a concern than a problem. the inlet hose is tight to the header. should i try to tie it back away from it?
you can also see the stud to the left. this is where the reservoir bracket bolts up and the "fork" end of the bracket rests on the inlet hose.


you can see in this pic if i push it towards the back of the oil filter i have about 3/16" clearance. i would have to zip tie it to the oil filter. should i ?

That powersteering bracket is supposed to bolt to the stud in the end of the heat exchanger end plate. When you try that you are saying it hits the header tube? Looks from the pictures as though it may fit.
There is also a 2008 and newer HP525efi square powersteering resirvior bottle with a different bracket that would probably fit also but I think its a pretty pricey part.

Best Regards,
Ray @ Raylar

Ray, yes I know where it is supposed to mount but the #1 cylinder tube is a lot further forward than the stock headers and the bracket doesn't fit. I may need to cut the fork off the bottom of the bracket and then drill a new whole for the stud to bring the whole thing forward about 1/2"

They look really nice, Sippy. I'm sure you'll get the minor details worked out. There seems to always be something even with the simplest "bolt on" product. How much did they cost? How are they better than the CMIs? Heavier gauge steel?

Better? The biggest thing IMO is that the outer tubes are larger diameter which results in more space between the inner and outer tubes allowing more water to flow through. One of the main reasons the stock headers inner tubes crack is due to not enough space between the tubes especially in the tight bends. This causes extreme heat in these ares. Seems to be more on the #7 and #8 cylinders with the tightest bends. It's not so much the heat but the extreme degree of cool down that will crack pipe. Check your pipes for blueing. Chances are your aft two tubes are blued esp on the inside.
Hardin headers are also heat treated, and hand crafted