Super Jet Cylinder exhaust manifold surface ding

[sharkcus]

I bought a brand new cylinder for my superjet. During shipping, something happened. (yes, it was insured) There was a puncture hole in the box and a pretty good sized chunk was taken out of the exhaust manifold mating surface (outer waterjacket area). We are filing a claim, but either way, I will need to get this fixed.

When it was chipped, some of the metal was pushed up making the surface not flat. I ground the protruding metal down so all that is left is the missing material.

I hate to even suggest this, but do you think I could fill it with jbweld or some other epoxy and sand it flat with the rest of the surface? Like I mentioned, this is a waterjacket area, so it won't get really hot and it won't be torqued super hard to the exhaust manifold.

 

[BruceSki]

yes i think that plan would work fine. If you wanted to go above and beyond you could weld it first and then grind it flat again. that would be the best solution but a bit harder if you don't have a welder.

 

[sharkcus]

I was thinking that too, but that would mean I would have to disassemble it all again (heat) and since there is still some material left, I was thinking a filler might do the trick. But I do see what you are saying. I guess if this doesn't work, I'll just pull the motor and have it done right.

 

[BruceSki]

Its only 6 bolts to pull your cylinder off. Easy since the exhaust is off already. You can leave the motor bolted into the hull. Hell you can even leave the head bolted on too.

 

[SUPERTUNE]

Jb weld will be fine...
Don't to weld it, any warpage and it will leak unless it gets remachined flat again.
You still have enough surface to seal even if you don't do anything but file the high spot off.
Make sure you torque the exhaust bolts to 24 ft-lbs.
Our XS 1000's have about that much sealing on the exhaust ports and they have more exhaust pressure and have no problems.

 

[oxnard111]

I was thinking the same thing as chucky... either jb or just run it.

 

[sharkcus]

K. I'll go that route. I agree about the warping. Plus, exhaust pressure wouldn't come into play, right? I mean, that's just the waterjacket mating surface. The exhaust pressure would hit against the inner gasket/surface.