Hull Hugger - new vs old (GT40 1997)

[FMSKI]

Do these mufflers lose their silencing / get louder with 1500+ hours? I am curious if a new one will make a difference there. I use ear plugs in the boat anyway, skiing (and cycling for that matter) due to wind noise. But my exhaust has a bit of a bark to it.

[Jonny Quest]

The 1996 to 1997 muffler was a bit different. My 2001 has the later model and it is fairly quiet IMO. It is likely that the muffler will lose some effectiveness with age. With 1,500 hours on the boat, the current muffler really doesn't owe you anything. However, to try a new will set you back $800+

JQ

[SilentSeven]

The internal baffles may be broken. IIR, there are some threads where people have cut open their muffler and done repairs....I'd review those as a starting point....

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[FMSKI]

Searching for threads... How do you remove the hugger muffler (easy way . Do all the pipes from the cast risers have to come off?

[SilentSeven]

Hugger as in the two port in, one port out muffler that's under the floorboard on a '97 ski?

To pull mine, I'd loosen all the muffler hose clamps, make sure each hose was broken free from the muffler (you know how hoses stick on over time...break that free) and sort of rotate the muffler out from the hoses. You take that aft end and sort of push it to the middle to get some space on one of the forward hoses and then wiggle it out. It's definitely simpler if you can scoot around the hoses on the manifold riser side.

If the muffler hasn't been pulled for a long time, getting the hoses broken free is likely going to be the trick.

Not that I've tried on a boat hoses, but I used a neat trick on how to slip off stuck bike handle grips and always wondered if might not work on a a boat hose. You basically get a bit of a crack between the handle bar and grip and flood the stuck area with rubbing alcohol. The alcohol wicks into the crevices and wallah! off slips the handle. It's been my plan b for boat hoses, just haven't had to pull any lately.

[FMSKI]

OK thanks - will try that rotate out trick. Yes the hoses are stuck on pretty well (25 yrs!)

[JayG80]

Art Cozier, who has forgotten more about CC than this whole board ever known, suggested WD40 to lube the exhaust hoses.

[FMSKI]

So hot here that after the day in the sun, I was able to just move the hugger bu ###r forward into the twin inlets, and then with lifting up/some english, popped off the back hose no probs.

Now the pad underneath was displaced so there is some wear on the hull and hugger unit. Baffles look OK tho, despite being a rumbling thing. Perhaps hitting the hull direct and creating that gnawing effect is where the noise was coming from. I thought there'd be a mesh or something inside.

I have a layer of epoxy and cloth to bolster the bottom of the b##gered hugger and then will EVA foam it top and bottom (heat molding style too!)