[ATTACH=CONFIG]564578[/ATTACH] look at the blue 3/4 hose that gets plugged

Thank you for the link, very interesting on the drain line plugged. I'll definitely look into that when I get back on the project, thanks again.


Update, washer found in the manifold............

http://i177.photobucket.com/albums/w...n.jpg~original

I was gonna suggest hooking some small rubber tubing to a Dyson vaccum. Don't ask me how I know this works!
Since you have a manifold off might as well replace the cast iron with early Merc aluminum models. Weight savings of 66lbs and the ports and runners look larger. Bought mine for $500 with 20hrs run time and sold mynstock iron for $350. I recommend it.

Got it, thanks.

Great minds think alike.........I hooked up my big shop vac necked down to a 1/2 " OD piece of hose, but to no avail because it was laying flat I'd assume.

On the manifolds, thanks for the suggestion but mine are feather weight aluminum already (2003 motor). Thanks

Should be done welding up all the risers and tails next week. The OEM Risers will be either vacuum or air pressure tested for leaks rather than water pressure tested as their heading to powder coating once finished with leak testing and having any residual water in the riser during powder would be a no-no.

If your going to do this mod, I'd like to mention that the OEM Risers have "LOTS" of weld splatter all over them and it'll take a little extra time to grind all that off before powder for the perfect look. Not that it matters but, I changed my mind on riser powder color..........bright silver instead of metallic purple, goes better with the polished tails.

Tailpipe ring material arrived Saturday, 2 pcs 1/4" thk x 6" dia. 6061 Aluminum round stock. I'll be machining these round plates to secure the seal between the tailpipe and transom. Material for the gasket seals also arrived Saturday, 3/16" thk. x 12" x 12" High Temp Silicone. Pics forth coming of the seals once there cut.

Two Aluminum Blanks for tailpipe rings, once machined they'll be powder coated white:

http://i177.photobucket.com/albums/w...d.jpg~original

Cut OD & bored out ID, ready for drilling bolt holes then off to Powder Coating:


http://i177.photobucket.com/albums/w...p.jpg~original

I'll be cutting the transom gaskets today as well, pics coming...............

Are you cutting a o-ring slot to seal around the pipe?

No, The transom gasket ID hole for the tailpipe will be cut to 3.875 for a 4.00 OD pipe. This will provide a water tight seal around the pipe to the transom. The gasket material is 3/16" thick and once it's clamped between the flange and the transom it'll provide tailpipe support as well as a water seal. Material is high temp silicone so heat is not an issue at all and I selected a Durometer 60A for the gasket, plenty stiff but yet flexible enough to work with. Pics forth coming mocked up on a pipe so you can see what I'm referring to...................