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Jet Ski Exhaust Repair

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  • Aeronca41
    replied
    Beautiful work, as usual, Don!

    Leave a comment:


  • Aeronca41
    replied
    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!

    Leave a comment:


  • MAC702
    replied
    Good point about the chamfer and squareness. I'm also assuming much less chance of joint contamination, too.

    Leave a comment:


  • Don52
    replied
    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

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  • Don52
    replied
    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.

    Leave a comment:


  • ryanjones2150
    replied
    For me, I’d use any excuse I could find to part something in the lathe over the band saw.

    Leave a comment:


  • MAC702
    replied
    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?

    Leave a comment:


  • Don52
    replied
    The last picture shows the exhaust manifold painted and installed in the jet ski.

    6. New cap welded in
    Click image for larger version

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    7. Two manifolds done
    Click image for larger version

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    8. Manifold painted and installed
    Click image for larger version

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    -Don

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  • Don52
    started a topic Jet Ski Exhaust Repair

    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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