Putting stuffers in a crossflow

[Gilera]

Hi everyone. I had a set of stuffers from a wrecked motor I bought ages ago. I finally got a replacement intake manifold gasket in the mail and decided it was time to put them in. I have never taken a manifold off an outboard before so go easy on me . . I can't remember how the stuffers were positioned in the motor they came out from. Do they just sit in the manifold next to the reed cages like in my photo? The previous person to take it off must have used some kind of sealant because I have having real hard time getting the old gasket off the casing. I thought the general recommendation was not to use anything on gaskets in the fuel path. Is it a good idea to put some gasket sealant on it or not needed?

One last thing, I noticed that there were grinding marks just in from the manifold (see photo). Is this from the factory or has someone tried to improve the flow? They are pretty rough.

[perfmarine1]

The marks on the stuffers from the screw heads should give it away. Now do yourself a favor and take the reed cages out and sand the intake down to make sure it is flat,they are all warped. I use a piece of bullet proof glass and a piece of sandpaper taped to the glass. Screen paper works best, 120 grit as per the book. Check the crankcase side with a good straight edge, any leak in this area and motor will run like crap. Ssand back-and-forth till flat then use a figure 8 pattern to finish for best gasket retention.

[perfmarine1]

Grind marks are factory, Here is what I use

[Gilera]

Thanks I'll do that. Do you also use sealant on the gasket. Yes I did see the screw marks and figured this was right, but when I did a test fit the intake doesn't sit up flush with casing due to stuffers sitting proud. I guess they just they just compress down when it's tightened up?

[perfmarine1]

Yes I use aviation form a gasket, it's non drying.And a great corrosion preventive.

[perfmarine1]

I thought about the position of your stuffers and I believe you have them in upside down.

[Gilera]

If they sit in that spot next to the reeds then I can't see how they could go another way. As mentioned there are imprints from screw heads. The only thing which seems strange is that they sit proud of the manifold. There is a small recess in the block where the intake mates up but even so it seems they will have to compress when tightening the manifold up which doesn't seem right. I had read there are different types of stuffers. I got these out of an 85hp (I think 1982model) so they had obviously been fitted by the previous owner. Perhaps the wrong ones for V4 crossflow?

[perfmarine1]

You are correct and I believe now you do have them in the right way I can't see them going in the other way, manifold will sit above and have to be compressed as you tighten the screws.

[sharpeye Mike]

Could someone fill the gaps with silicone instead?
Like maybe a seal and peal type.

[perfmarine1]

A tube of Silicone should not be within 10' of a crossflow rebuild ever...

[sharpeye Mike]

I was looking at the stuffers and thought there was room for improvement.

[Gilera]

I am having trouble getting these stuffers in. I did a mock up without the gasket and tightened up. When I took the manifold back off the edges of the stuffers had been pinched between the manifold and the case which is what I was concerned would happen due to them sitting proud. Any suggestions? Is it possible that the stuffers are meant for a different motor?

[omcforever]

V4 and V6 stuffers are different.

[Gilera]

They came out of an early 80s 85hp so wouldn't have been factory in that motor I'm guessing. Maybe it is 4 out of 6 stuffers from a V6 then. I can't see why they would be intentionally made to protrude from the manifold.

[Dave S]

Watch the Movie ..... STUFFF.......... old Horrar clik.... like Killer Tomatoes......