The exhaust manifold on my customers 1996 personal water craft (Jet Ski) was a sand casting that had two concentric tubes; an inner tube and an outer tube. The exhaust goes through the center tube and lake water goes between the two tubes. There were two holes on each side of the manifold that which I assume were used to remove the core sand from between the two tubes of the casting during manufacturing. The four holes were blocked off with caps that were welded on during manufacturing. Over time the water corroded the caps so that there were eventually two pin holes in one of the caps. My customer carefully cut off all four corroded caps and made new ones. I enlarged the holes to remove the oxidized material on the ID of the hole, because I was concerned that the contaminated material would get sucked up into the weld and contaminate it. Then I welded the four caps in place. I am guessing the a new manifold would have been pricy.
Don
Don
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