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Head pipe assembly rupture

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1997GTX

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Last week I took my 97GTX for a run after an extended layover. It has a total time of 80hrs and has been winterized and looked after as per the manual. About 15mins into the ride I noticed the note of the engine changed a little and shortly after the ski felt "loaded up".. I headed back to the ramp and it had obviously taken on a LOT of water.. When I removed the seat i was stunned to see the hull was full ofwater (over the top of the battery)..

I couldn't see any obvious leaks/ pipes off etc so got home and rinsed it all out and gave it a run through, which was when I noticed that one of the 4 casting points on the Head Pipe assembly(underside) had blown out and the water was running directly over the engine and into the hull.. Has anyone else had a problem with this and i'm assuming this must take the place of a welsh type plug etc.. is this the case, or is my situation a one off?? I've seen this in a large marine diesel but not on one of these..
 
nah, not 1 off, had same thing w/ my ski/boat, used jb-weld, if you can find "bung"..mine cracked there, so patched up. If pipe is aluminum and not "pop" metal, then you can have fab shop fix'ur up.
JB-Weld or this stuff, "seal-crete", believe its called, (wal-mart..etc, RV/Boat area),grey stuff....
 
That is a common problem on Doo exhausts. I've used JB Weld before in a pinch but I prefer to grind off the thin remaining material and weld an aluminum patch so I know my customers will never ever have to worry about it again. The thing with JB weld is that the material that is left will still be corroding away and eventually the JB will let go as well because what you put it on disappears.
 
Thanks guys.. Appreciate the feedback.. Found a marine guy who does TIG welding so that should do the trick.. :)
 
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