PDA

View Full Version : Pinhole Leak


shepherd
02-24-2008, 08:08 PM
I found a small pinhole leak in my aluminum exhaust manifold today. :(
This can be welded, right? Also, would it hurt the engine if I ran it like this until I could get it fixed? I think not, but I've been wrong before!

shepherd
02-24-2008, 08:10 PM
A wider angle shot.

03 35th Anniversary
02-24-2008, 08:32 PM
I wouldn't think it would hurt anything with that being the end of the line for the raw water before it leaves the boat.

6ballsisall
02-24-2008, 08:41 PM
Looks serious Shep. Drop that boat off at my house and you can pick it up this fall, fixed of course. ;)

shepherd
02-24-2008, 08:48 PM
I wouldn't think it would hurt anything with that being the end of the line for the raw water before it leaves the boat.

That's pretty much what I figured. I thought I'd give someone the opportunity to come on here and say "Don't do it man!"
I suppose it would be a pretty easy fix for an experienced welder of aluminum thingies....

shepherd
02-24-2008, 08:49 PM
Looks serious Shep. Drop that boat off at my house and you can pick it up this fall, fixed of course. ;)

Thanks jr, but I can slap a wad of chewing gum on there as easy as you. ;)

88 PS190
02-24-2008, 08:50 PM
Radiator repair shop.

They can patch that with aluminum solder rod, easy. Its just like repairing a radiator fin.

TMCNo1
02-24-2008, 08:55 PM
I would have thought those manifolds were thicker than that. Is that a dent in the aluminum or was that the way it was cast.

6ballsisall
02-24-2008, 09:02 PM
Thanks jr, but I can slap a wad of chewing gum on there as easy as you. ;)

You never can be to sure about these things Shep. It's all ball bearings these days you know......

03 35th Anniversary
02-24-2008, 09:49 PM
Thanks jr, but I can slap a wad of chewing gum on there as easy as you. ;)JB Weld!!!!!!!! ;)

shepherd
02-24-2008, 10:00 PM
I would have thought those manifolds were thicker than that. Is that a dent in the aluminum or was that the way it was cast.

They were cast that way. The other one has the exact same bumps. Now, I can't account for the scratches all over them though. They were there when I bought it.

T Scott
02-24-2008, 10:10 PM
Shep....Let's see a pic of that engine....zoomed out! Looks Bad A$$!

T Scott
02-24-2008, 10:10 PM
Shep....Let's see a pic of that engine....zoomed out! Looks Bad A$$!

atlfootr
02-24-2008, 10:40 PM
I found a small pinhole leak in my aluminum exhaust manifold today. :( Chew some gum, ya already know the rest of the story :D

atlfootr
02-24-2008, 10:44 PM
TBro,
What'a try 2 do? Jack up ur post count -- LOL :uglyhamme

kjohnson
02-25-2008, 07:21 AM
When did MC start using aluminum manifolds?

shepherd
02-25-2008, 08:34 AM
It's the LQ9, Cadillac engine. I don't have a good pic of my engine, but I think 03 35th Anniversary posted some of his. His looks better anyways, with the supercharger and all... ;)

TMCNo1
02-25-2008, 09:23 AM
When did MC start using aluminum manifolds?


All I have ever seen them on was the '03 Anniversary LQ9's, they may be on other LQ9's that had that engine option, but I don't remember seeing them.

mayo93prostar
02-25-2008, 01:07 PM
shep, your slacking, it looks like they need some polishing after you get the hole fixed. be careful if they weld it on the boat to not burn the rug or upholstery.

flipper
02-25-2008, 01:12 PM
That should be an easy fix. If you don't do it yourself, a radiator shop would be your best bet.

stuartmcnair
02-25-2008, 03:50 PM
truly pathetic...I thought with all the mechanical genius on this board someone would have suggested the obvious..

http://www.adhesive-duct-tape.com/images/duct-tape.jpg

flipper
02-25-2008, 04:45 PM
truly pathetic...I thought with all the mechanical genius on this board someone would have suggested the obvious..

http://www.adhesive-duct-tape.com/images/duct-tape.jpg


Your right, we all over looked the obvious.....:noface:

hydro-therapy
02-25-2008, 05:29 PM
5 minutes at a local welding shop flat rate fee probable under fifty bucks or one free trip to your local lake 26 mph 15' feet off end result boat fixed - new mechanic located - "Life is Good"

stuartmcnair
02-25-2008, 10:09 PM
Your right, we all over looked the obvious.....:noface:

c'mon...there was a little sarcasm to that. :D

rob935
02-29-2008, 02:14 PM
should be very easy to weld up the small hole but bring to a specialist aluminium welder. i wouldnt run the boat until you get it done tho.

Sodar
02-29-2008, 02:17 PM
I just saw this. I cannot tell if it is a riser for a LQ9 or not. Looks like it is the wrong side too...

I dunno...
http://cgi.ebay.com/ebaymotors/FACTORY-MASTERCRAFT-EXHAUST-HEADER-NR_W0QQcmdZViewItemQQcategoryZ31285QQihZ024QQitemZ 370026890518QQrdZ1QQsspagenameZWDVW

TI Skiier
04-12-2010, 12:41 AM
I have this problem on my X7 with an MCX. I am thiniing of using
jb weld to fix. Anyone have experience with it?

slickwater1
04-12-2010, 08:58 AM
anyone with a tig rig or an aluminum spool gun can fix that in ten min. make sure they know how thin it is so that they don't apply to much heat, it will make a larger hole. please don't use JB weld, it is a quick fix for an ever present problem. not saying it won't work but chances are it will come off and still have to have it fixed at a later time.

macattack
04-17-2010, 04:02 PM
Investigating why my bilge came on today, I found a stream of water shooting out from one of the "bumps" on the inside of the exhaust manifold. It appears there are 4 bumps on the inside and 4 on the outside of each manifold and each one has a 1/4" white/crusty circle in the center. So, I guess all these bumps are corroding at the same place and are about to break through. Very, very disappointing since the engine only has 400 hrs, used only in fresh water lakes and stored in a garage:mad:.

1. What's up with these bumps and why are they corroding?
2. Can you drill out each one and JB Weld?
3. Guess you will need to remove the exhaust manifolds to reach/drill out the inside ones, is there a gasket that will need to be replaced?
4. What's the torque for the exhaust manifold bolts?
5. What else do I need before I start this project?

Is everyone having this problem after 400 hrs or so? Did Indmar fix the weak points in the exhaust manifolds after 2005? tks, mac

03 35th Anniversary
04-17-2010, 04:15 PM
Is water coming out of those places when it is Hot and Running?

macattack
04-18-2010, 08:23 AM
Yes, while the engine is runninng. So far, water is just coming out the bump on the inside of the manifold that is shown in the picture that I stuck a wire in to see if the hole went all the way through.

MC240
04-18-2010, 08:51 AM
Slickwater is right. Take to a shop that has a high-frequency "wet" TIG rig. Make sure battery is disconnected, especially if your engine has electronic ignition or other electronic parts. This type of welding can disrupt those parts.

ncsone
04-18-2010, 09:34 AM
Mac - I am keeping an eye on this thread as I have the same boat, same motor and I am starting to see the same spots on my manifolds. Please post your fix on here as soon as you resolve it.

macattack
04-18-2010, 07:09 PM
Well, Indmar answered my weekend email, but not exactly the answer I was looking for...explained why the welded plugs are there and corroding, but that is just the way it is:(

"Those bumps are plugs that get welded into the manifolds after they are
cast at the foundry. The holes that are plugged with the welded in plugs
are there to let the core material (sand) out of the manifold after it is
cast. The manifolds are aluminum and the plugs are also aluminum but a
different alloy than the manifolds. They are more electrically active than
the manifold so if there is any electrolysis occurring, the plugs will be
eaten away before the manifolds are. The plugs are serving the function of
anodes.

You have several options for repair. One, you can replace the manifolds
with another set of ETX manifolds, two, you can take the manifolds to a
welding shop and have the old plugs removed and new ones tig welded in
place. We have replacement plugs available. To prevent the problem from
re-occurring,I suggest that when you take the boat out of the water that
you disconnect the hose that connects the manifolds together and let the
water drain from the manifolds. The third option is to replace the ETX
manifolds with conventional cast iron manifolds like have been used on
these engines for years.

You can do a temporary fix by plugging the hole corroded in the manifold
with epoxy or some other water proof material but the aluminumplug will
eventually be eaten away and a more drastic repair as indicated above will
be required."

So, it sounds like this is an aluminum vs cast iron manifold problem??? Such a bummer!

macattack
04-19-2010, 09:41 AM
It just gets better! I sent Indmar some follow-up questions, here's their response:

"Electrolysis occurrs when two dissimilar metals are exposed to an electrolyte. In this case, the dissimilar metals are cast iron in the engine block and aluminum in the exhaust manifolds. The electrolyte is the water. Normally, fresh water is a very poor electrolyte but in some cases because of mineral levels or salt in the water, the water is able to conduct electrons. This allows the electrons to be removed from the more active material, in this case aluminum. Electrolysis will attack the most electrically active material, the one that gives up electrons the easiest, first.

Electrolysis does occur more readily in aluminum than cast iron because aluminum is a more electrically active metal.

The manifolds were changed to aluminum because that particular design, one piece header style manifold, was not practical to make out of cast iron.

A warning about draining the manifolds was not put into the Owner's manual because we did not anticipate that there would be an issue with manifolds used in fresh water. In fact, a vast majority of the customers with these manifolds have not had any issues."

So, it appears Indmar was aware this problem would occur with their aluminum manifolds, but didn't put a warning in the owner's manual about draining the manifolds after each outing because they didn't anticipate an issue with fresh water usage. Well, obviously there is a problem with fresh water usage since I only use my boat in fresh water lakes!

Are other owners having this same manifold corrosion problem and what does everyone think about Indmar's responsibility at this point? tks, mac

macattack
05-07-2010, 01:53 PM
Just to wrap this one up...MC finally returned my call/email after 2+ weeks:(. I talked to Joe who is the Indmar rep at MC; nice guy, but basically said my engine is out warranty (3yrs) and there were no recalls on the exhaust manifolds. The design worked as far as the casting plugs corroding before the exhaust manifolds even though the boat was only used in fresh water lakes.

I did email back & forth with Larry at Indmar; he was a little more helpful by at least sending me the 16 replacement aluminum plugs and new decals at no charge.

I guess my suggestion at this point would be for MC owners with aluminum manifolds, who are within their 3 yr engine warranty, to keep an eye on these plugs. I would contact your local MC dealer at the slightest hint of paint starting to flake off in the center of the plug since that would be your clue that the plugs are about to start leaking.

At this point, I used JD Weld to plug the 8 holes until I have time to take the manifolds to a weld shop.

mcmx2
05-07-2010, 09:48 PM
Mac,

You have gotten further than I did with Indmar. I have the same boat as you 2005 TT 197 #77with the LQ9 engine and I started getting water from the casting plugs @ around 380 hours last summer. By 420 hours I had JB weld on at least half of them and the rest were ready to go. Indmar basically told me that I would have to call a dealer and order new manifolds. I found a used set with around 100 hours on them at a dealership that had taken them off a boat to put on stainless for saltwater use (thanks Jim at BAWS). I am planning on taking the old ones to a welding shop and getting them repaired and then I will have a spare set when these go as I now have 460 hours on the boat and these are sure to go eventually also.