Upon launching this year I had a leak in the starboard exhaust hose/flange area as it exits the transom. The rubber is very hard and probably cracked. I suppose the flange could be cracked but won't know until I get it apart. In any event it was leaking pretty badly.

All the hoses seem to be very old, probably original. So I plan on buying enough hose to redo the whole system on both sides. I'll repair what leaks now and leave the rest for a winter project.

The system appears original to the boat and seems to use both 4" OD at the leak & 5" OD hose closer to the engines. My question is, does that dimension sound right and if so, would anyone know the ID offhand? Also, does anyone have a good source for the hose? I'm thinking I'll need 2 feet of the 4" OD and maybe 4 feet of the 5" to do the whole thing. 

One last thing... if anyone has tips for getting the old hose off and the new hose on, I'd be eternally grateful!

Here's where it's leaking. Thanks in advance!


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I did mine a few years ago, from the Y-pipe to the elbow is 4” hose, from the elbow back is 3-1/2” hose. I opted to remove the copper pipe from the system to possibly quite it down slightly, but noticed no real change. that would save you probably 4ft worth of hose right there. The only way I got the old hoses off was by slitting them with a good razor.

http://commanderclub.com/forum/topics/31-exhaust

Thank you Mike! Your link is just what the Dr. ordered. Question for you, the hose dims you mentioned, are those ID measurements? All I could get yesterday was OD, so if yours are ID measurements I'll know just what to order.

And... the photo of replacement mufflers could be an excellent way to go, if mine turn out to be all rusted out. Thanks again!!

Mike H said:

I did mine a few years ago, from the Y-pipe to the elbow is 4” hose, from the elbow back is 3-1/2” hose. I opted to remove the copper pipe from the system to possibly quite it down slightly, but noticed no real change. that would save you probably 4ft worth of hose right there. The only way I got the old hoses off was by slitting them with a good razor.

http://commanderclub.com/forum/topics/31-exhaust

Those are ID for the hoses, od for pipes. Kerhig built those mufflers for me, they still have the plans. I have been very happy with them, they sound just like the original cast iron mufflers and will probably out live the boat. They’re not cheap, but not really much more than higher end mufflers. 

Well I've got it taken apart. I used a box cutter and the hose came right off. I'm thinking I'll clean up the muffler flange and maybe coat it with JB Weld or something, to give it more stability. The fiberglass transom flange looks to be in very good condition.

So now, how to get the new hose on? There's obviously not enough wiggle room to slide on an 8" piece of hose thru this 1" gap. So I assume I'll also remove/replace the hose on the left end (in the photo) of the muffler. I'm guessing I'll need to assemble the area nearest the transom first with the muffler unmounted. Then slide it all together working from the end nearer the engine. Does this sound right? Any tricks or advice?

Surprised a box cutter got it.  Usually I would expect wire reinforced hose.  You may need to go back to the Y pipe and let everything swing to get this assembled.  Glad it's you not me.  Good luck.

I removed everything, so I didn’t have to fight with other hoses. But I started at the transome and worked my way forward. Depending on whether you have a copper pipe infront of the muffler or not there my be enough flex in the system to get that piece on in the back. I used some dish soap to help the tight pieces on. I don’t think I would put any JB Weld on there, the fit is pretty tight already. Also be carful how tight you make the clamps on the fiberglass, you can crush it.

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