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Jet Ski Exhaust Repair

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  • Jet Ski Exhaust Repair

    The exhaust of a Jet Ski is a casting with an inner pipe and an outer pipe. The exhaust goes through the inner pipe and water goes between the inner and outer pipe. During the casting process a sand core is necessary to form the cavity between the inner and outer pipes. The casting is designed with holes on the outside to support the core and to drain the core sand. After the casting is complete caps are welded on to cover the holes. The material of the caps is more susceptible to corrosion than the casting, so they act as a sacrificial anode and corrode first. Attached are some pictures of the process that I used to replace the caps on two exhaust manifolds.

    1. Manifold with damaged cap
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    2. Close up of damaged cap
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    3. Damaged cap ground off
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    4. Paint ground off
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    5. making new cap
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    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    The last picture shows the exhaust manifold painted and installed in the jet ski.

    6. New cap welded in
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    7. Two manifolds done
    Click image for larger version

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    8. Manifold painted and installed
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    -Don

    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      Very nice work.

      What material is the new cap? Keeps sacrificial anode properties?

      Any special reason for lathe parting instead of bandsaw, or just because?

      Comment


      • #4
        For me, I’d use any excuse I could find to part something in the lathe over the band saw.

        Comment


        • #5
          Originally posted by MAC702 View Post
          What material is the new cap?
          6061-T6 Aluminum

          Originally posted by MAC702 View Post
          Was the material selected to keep sacrificial anode properties?
          No, it was what I had on hand.

          Originally posted by MAC702 View Post
          Any special reason for lathe parting instead of bandsaw, or just because?
          Using the lathe I could square up the bar, ensure a parallel cut and chamfer the edge.
          Miller Thunderbolt
          Smith Oxyacetylene Torch
          Miller Dynasty 200DX
          Lincoln SP-250 MIG Welder
          Lincoln LE 31 MP
          Lincoln 210 MP
          Clausing/Colchester 15" Lathe
          16" DuAll Saw
          15" Drill Press
          7" x 9" Swivel Head Horizontal Band Saw
          20 Ton Arbor Press
          Bridgeport

          Comment


          • #6
            Originally posted by ryanjones2150 View Post
            For me, I’d use any excuse I could find to part something in the lathe over the band saw.
            I agree. If you have a nice tight lathe it is easy to use the parting tool.

            -Don
            Miller Thunderbolt
            Smith Oxyacetylene Torch
            Miller Dynasty 200DX
            Lincoln SP-250 MIG Welder
            Lincoln LE 31 MP
            Lincoln 210 MP
            Clausing/Colchester 15" Lathe
            16" DuAll Saw
            15" Drill Press
            7" x 9" Swivel Head Horizontal Band Saw
            20 Ton Arbor Press
            Bridgeport

            Comment


            • #7
              Good point about the chamfer and squareness. I'm also assuming much less chance of joint contamination, too.

              Comment


              • #8
                Originally posted by ryanjones2150 View Post
                For me, I’d use any excuse I could find to part something in the lathe over the band saw.
                Yep!

                Comment


                • #9
                  Beautiful work, as usual, Don!

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