FAE: Out of Retirement

[UNSTUCK]

mchirpich hooked me up with his old FAE that had just been rebuilt to new last week and I quickly put it to good use. Its intended use was on a Z3 but after checking with FAE they told me this would work on my rzx. Really the only guess was if it would reach around the TAPS plate. Ended up clearing by about a 1/4". Perfect! I was originally planning on removing the welded on flange and adding material to the "intake" end and then welding on a new flange so that it would resemble the newer style (less mandrel bends) intended for the rzx's, and then not using a support rod. Well then the Mrs decided to destroy one of our garage doors last week, so there went the funds. This ended up getting put on for as cheap as possible.
I drew up and CNC cut a new support bracket out of 3/16" stainless then spent a bit of time polishing it to match the polish job of the TAPS hinge... just short of mirrored. I then just needed to shorten the support rod that came with the exhaust. I'm very happy with the finished product and even happier with the overall price: a grand total of $324. I think the new ones are about a grand from dealers ???

This being the first FAE I've had in my hands and really getting to look at it, I'm once again a bit disappointed with the build quality. I have expressed disappointment in the past about weld quality I've seen from pictures, and this one is no different. In the end, I think I'm glad I kept the support rod as I don't think the welds could support the stress on their own, hence the move to mandrel bent tube. The little tube they "weld" on the FAE for the support is just hideous. Why not just machine a very simple part that fits the tube right and makes for a nice weld? Speaking of welds, I noticed they didn't back purge the SS tube when they welded it. This causes the weld on the inside of the tube to oxidize. Oxidation allows the weld and the tube around the weld to rust. So at least mine and probably everyone's are getting eaten up from the inside out.

My first bracket's neck was 1/2" too long. Measure twice, cut once right? Anyways it shows my attempt at polishing. I have very little experience polishing parts. Turned out well enough.
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Tomorrow is the big test. I look forward to the boat running a bit quieter. Thanks again Mike for the good deal on the FAE!

[lilkw]

Did you happen to take a picture of the pipe before you bolted it on?

[whiteflash watersports]

If you think it is rusting or going to rust from the inside out I will be screwed as we are in brackish water 50% of the time. I am diligent with flushing and a detailed wash after every outing but still. Had ours for about a year so I will be keeping an eye on this.

[UNSTUCK]

Did you happen to take a picture of the pipe before you bolted it on?

I didn't. I guess they changed it to the new design when it went in for warranty work. That could be wrong though. Anyways, there is a small flange welded to the tube about 2 inches from the inlet side. It has four elongated holes to allow for angle adjustment. Then there is a floating mounting ring outside of that flange. You can kind of see those two parts in these pictures. You just can't see the 2 inches of inlet tube that is inside the black plastic flapper housing.

If you think it is rusting or going to rust from the inside out I will be screwed as we are in brackish water 50% of the time. I am diligent with flushing and a detailed wash after every outing but still. Had ours for about a year so I will be keeping an eye on this.

To be honest, I don't know. There will be a few guys that will pop up here and say they've had theirs for 10 years and no problems. It might be a non-issue. I just know the correct way to weld SS tube, and know they didn't do it that way. For this application it may not matter, but at the same time they chose to use SS for a reason. I have assume rust prevention and good looks. Maybe for shaping the tip. It's brushed, not polished, so it doesn't match the TAPS plates, so it doesn't look as good as it could. I like the contrast so it's okay in my book that it doesn't match. It shouldn't rust on the outside so that's good. Just the oxidized sections on the inside, along the welds. Aluminum could have been used for all of that and never have a rust issue. Not sure how well it could be shaped though. They may have had to fabricate the tip instead of molding it.

[Germaine Marine]

You can machine polish the older units to look killer

[UNSTUCK]

Yes, I will try to polish it up a bit.