Glastron Surface drive

[CharlieN]

I am progressing with building the exhaust risers.
These are made in 304 SS, the inner tube is the same diameter as the collector on the headers, this being 2 1/2 OD, the headers themselves are metric with 40MM runners. Bought them on Ebay in the Middle East from a country I can not pronounce. After they were delivered I have seen them listed in California for more than double the price including what I paid for the shipping.

[CharlieN]

Not a big thing but the exhaust risers are finish welded and rough polished. I will do a bit more detail work then it is time to align and weld them onto the headers.

Then real fun begins, building the water jacket for the headers. That will be time consuming.
I spent many hours searching for a nice set of aluminum EX manifolds , anything that looked nice is way out of my reach financially. There was a nice looking set overseas but they never responded.
So here are my risers, soon to be welded to the headers.
I ended up installing one O2 bung each side, I was originally thinking I should have two on one side so a wideband meter can be run. I expect I can get that info from the engine control unit.

[David - WI]

My wideband O2 meter also outputs a narrowband signal for an engine ECU if needed. So, you just put the wideband sensor in the exhaust and then hook the stock ECU O2 wire to the WBO2 meter output instead of using the narrowband exhaust sensor at all. (Also, it has -I think- four EGT inputs and a couple other analog channels).

[CharlieN]

That is a nice setup. This engine runs wideband sensors, kind of a surprise but seems to be part of modern emissions designs. From my readings the engine will to some point learn and tune as it feels it needs. Curious if this will be true but other than freer intake and EX systems I am not changing much.
Heck I considered trying the factory 4-1 exhaust but these street rod headers have far better formed tubing.
I was just setting one collector/ exhaust hose in place but the hose clamps are in hiding or I just have not bought them yet.

[David - WI]

The meter will also pass the wideband signal through to the factory ECU... so either way you just need one sensor (or one per side).

[CharlieN]

One per side for this one, good info.
I am far enough to set one exhaust in place, I like how it sits.

[CharlieN]

Kind of like yesterday, I have the Starboard side EX set in place. Both sides need minor tweaking where they will mate to the headers. I will then be ready to tack weld both sides. Then they are ready to finish weld the sections.
Next will be remove both sides and fully weld the risers to the upper pipes together.
THEN, fabricate the water jackets for both sides. I will not be rushing that job. I have been searching online for an affordable set of Aluminum EX manifolds, as in under 1K. Nothing real that I could find, so I will continue with these.

My wife and I are hosting a few aviation events in the near future and they will draw my attention at times.
Our upcoming fly-in breakfast looks like it will be better staffed than the past few years with help coming in from other EAA chapters as well. Seams they are curious how we feed well over 100 people with just 8 souls working. Heck we are too, just takes people with pride and trust in our leadership.

[skialot2]

Loving this thread. Especially this exhaust build part. Very impressive. It's waaaay past my skill level.

[CharlieN]

Thank you, I am enjoying this stage of the project. As we all know not everything goes as planned but this EX is actually coming along as desired.
The next stage on this EX I expect to become tedious, but not stupidly so.
One thing I am considering at this point, once the risers are partially welded to the headers I am considering puling the engine and put it back on the work stand.
CN

Loving this thread. Especially this exhaust build part. Very impressive. It's waaaay past my skill level.

[CharlieN]

With all the other event and spring time stuff going on I got some time to get the PAX seat on rails and ready to do the first trial mountings.
Unfortunately for me my trusty Cannon camera decided when it shows 9999 images it simply shuts down. Dang these cameras must be gold now. My Social security does not give raises.
I have a pile of SX60 camera, half a dozen that were dropped or simply quit.
I guess I need to use my wife's old SX40 handme down and get some images.

Where I am at, both of the original front seats are mounted on adjustable rails. More important on the pilot side since I am building with a foot throttle.
Pax side being adjustable? mostly for convenience if the rear seat is occupied.

Being neither seat is in place photos will not say much.
I could and should get images of the seat rail setup for people to ponder over.

[CharlieN]

I achieved an important step today, I have the EX risers tack welded to the headers.
At this point, other than the water jackets over the headers both sides are complete through the transom.
Once I look everything over I might pull the engine allowing me to finish the engine bay. That will be a big step.

For some reason I can not load the three images, well it does not look any different.

I have been trying to load a few photos, for some reason I can not do so.

[CharlieN]

Recently I commented that my Canon camera stopped taking pictures when this image count hit 9999.
I did a few hours searching online both searching for a replacement or a cure. I got a few decent opinions.
Then I started looking closer at the memory card, turns out it was full. I deleted 700+ images that date back a decade or so, heck they are on two computers hard drives.
The camera is working just fine when the memory card has room on it.
At this point I can move forward.

[CUDA]

Wow!

Cool

[89LASER]

Beautiful work! I've been following your build since I have a couple of Glastrons.

[CharlieN]

My next task is to remove the engine and drive so I can finish the headers, it is time to build the water jackets..
I spent some time this morning looking at the images of this project since my wife was saying the engine was installed with a neighbors heavy equipment, not my 24HP Kubota. Photos show I did install the engine with my tractor and my neighbor used his equipment when we flipped this hull when I verified the bottom of the hull was in top shape, It is, this hull looks like it was never beached of run over anything. I sanded the bottom as recommended and polished & waxed the sides of the hull.
Well I making a weather related scheduling error. Originally we had inbound rain coming about 5 Pm, The boat is in a carport under our hot tub room nice and safe.
I was just outside and it felt like WX was approaching soon and sure enough we have light rain upon us now and going to rain for a number of days. So much for the headers and working on the inside of the hull. Heck this is the same time as yesterday when the rain arrived at our fly-in breakfast which allowed us to at least brake even and hopefully make some money for our EAA chapter.