bajaman

I too find it a bit odd that they are talking about a mock up...frankly haven't heard of that when it comes to a supplier simply providing a system that is a replacement for a Mercruiser factory unit. Baja was a great builder in those Bucyrus days, good craftsmanship. They built 152 of your model boats that year, so I imagine they had a reliable, repeatable process for installing exhaust systems. As PQ290Enticer noted, you should have some 'wiggle room' with the rubber hose part of the system, won't you?

Joeyboost

So I called Eddie Marine again yesterday and spoke to a different person, seemed to be a bit more knowledgeable on this situation. I told him I have a 96 Baja 252 with an untouched transom but my current 502 is equipped with a Eddie Marine thunder manifold & cast riser setup. I simply want to switch out the cast risers for the SS risers and eliminate the T/Y for the silent choice and have the riser meet directly to the exhaust tip which I believe is also an Eddie Marine replacement.

I then told him I had spoken to a team member of his previously but I was confused as to why I would need to perform a mock up when this is a Bravo 1 factory original setup. He told me the replacement SS risers "should" line right up and yes they can weld in the O2 bungs and I am looking at about a 2 week turn around but for the mock up he would prefer I do it and take measurements for confirmation of fitment. So basically they believe it will fit but if it doesn't, don't call them back to ***** because you have been WARNED. Typical CYA scenario.

I'm on the fence on wither to wait until the engine is back from the machine shop or to just hope for the best. I think I can take the measurements with the engine on a stand and not in the boat but I'm a long way from getting it in the boat and it seems like summer is a long way out but in reality it really isn't at all!

I'm doing this for 2 reasons:
A. I want to bump up the cam profile slightly
B. I'm eliminating the silent choice and installing complete Holley HP multi-port injection system to eliminate the stone age MPI system it currently has with a MEFI 1 ECU.

PQ290Enticer: judging by your photos it looks like a direct replacement, where you have the rubber tube I have the silent choice TEE so I do not have any rubber tube just 4 couplers which makes me believe as long as the overall length is correct the angle from riser to tip should be fine. If it comes up short I can lengthen it with a pice of that rubber hose, it its too short I assume I can cut it in a band saw? Angle is the elephant in the room here!