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  1. #1

    Default Crusader 8.1 - Exhaust manifolds

    Well our pair of 8.1s had failing exhaust manifolds early last fall. this caused us to have to pull the boat and miss the fall Black Sea Bass and Striper seasons. We pulled the starboard first because it was the worst and we did not know exactly what we were in for. What a job replacing both exhaust manifolds. what we learned from that engine we used to work on the port engine without removing it. The outboard manifolds on both engines had be replaced with both inboard manifolds being significantly reworked. Additionally there were a zillion little (and not so little) items that had to be addressed. Out of 32 exhaust manifold bolts, half of them broke off. We also increased the depth of the thread by about a 3/16ths inch allowing a slightly longer bolt. After couple short sea trial runs, we took our Black Fin Combi offshore last weekend. Our hard work paid off with both engines, and the boat overall, running without a hick up. We also limited out on Black Sea Bass. Yahoo!!Click image for larger version. 

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  2. #2
    Join Date
    Sep 2008
    Location
    Maryland - USA
    Posts
    8,285

    Default Re: Crusader 8.1 - Exhaust manifolds

    good job! looks like the outlet gasket had been leaking for a while based on the pic...

  3. #3

    Default Re: Crusader 8.1 - Exhaust manifolds

    Quote Originally Posted by makomark View Post
    good job! looks like the outlet gasket had been leaking for a while based on the pic...
    Thanks. It took a lot of work to bring the head side mating surfaces (and reused manifold surfaces) back to nearly level around the gasket contact areas. We used Remflex gaskets (http://catalog.remflex.com/SearchRes...sp?Search=2058) and followed the directions. If these gaskets continue to perform as advertised, then I would highly recommend them to anyone in the same "boat". BTW we used Sierra replacement manifolds and found that we had to modify them a bid as they would not mate up to the heads. We discovered that there was not enough clearance for some of the tall head bolts. We had to first figure out what the problem was, identify the bolts then grind away just a bit of manifold material to make room for 2 head bolts. We skimmed just bit of material off the head bolts as well. This was true for both of the new manifolds, one on each outboard side. Luckily with the one engine out, we were able find and correct the problem with having to hang and rehang the new manifold about 5X. We knew right where the problem was on the port engine which we did not remove to do the work.

    Click image for larger version. 

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  4. #4
    Join Date
    Dec 2008
    Location
    Bourne, MA, USA
    Posts
    332

    Default Re: Crusader 8.1 - Exhaust manifolds


  5. #5

    Default Re: Crusader 8.1 - Exhaust manifolds

    2007 with about 2,500 hrs.

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