[C320-list] Fw: Leaking Muffler - Repaired

[Mike Ott]

I thought I would follow-up on my repair job since more than a few members 
expressed similar frustrations (Catalina still can't find a replacement).  I got 
the muffler out okay, thanks to Allan Field for his hair dryer suggestion to 
soften the exhaust hose.  I ground down the flange edge to expose the seam 
and routered the area with a dremel tool.  I pasted marine epoxy on the edge and 
let harden overnight.  In reviewing the muffler installation, I didn't like the 
gellcoat to gellcoat contact between the muffler and the mounting pad.  I bought 
some 1/2" vinyl tubing and cut out a 1/4" groove along the side.  I lathered the 
flange edge again with epoxy and formed the tubing over the edge forming 1/8" 
cover around the flange edge.  I had routered out an old piece of plywood, 
making a 1/2" canal, which made a nice jig to hold the tubing onto the flange; 
weighted the muffler down with a bucket of sand and let it cure overnight.  Ran 
the engine this morning for a hour, no leaks and now I have a vinyl gasket 
between the mounting base and the muffler, to absorb vibration.  Total work time 
(not count beers consumed while waiting for epoxy to cure overnight) : 4 hours.  
Total cost: $14 ( 2 tubes of marine epoxy from Home Depot and 10' of tubing). 
Mike
"Amanda Lu"
#508



----- Forwarded Message ----
From: Mike Ott <wmo48 at yahoo.com>
To: Catalina 320 Association <C320-list at Catalina320.com>
Sent: Tue, April 26, 2011 4:02:07 PM
Subject: Leaking Muffler


While doing my pre-lunch engine check on the Yanmar, I noticed water building up 
around the shaft stuffing box. Tracking it back to the muffler flange, I was 
hoping beyond hope that all I had was loose exhaust hose clamps, I tighten 
everything ... no luck.  Mopping up the water I noticed seepage under the fwd 
flange of the muffler.   Pulling that sucker appears to be the only answer.  
Anybody have this fun before?  Any nice ease hints? I think my approach at this 
point would be to grind the area, Marine-Tex the seam, and then glass over 
with some fiberglass mat or cloth.  Pulling the exhaust hose from the wet elbow 
to the input nipple on the muffler looks like it is going to be fun (almost as 
much fun as pulling it back on).  Good thing I have a couple of weeks until my 
launch date.  Would welcome some opinions / advice.
Mike
"Amanda Lu"
#508