Agreed, what you can do, is use aftermarket manifolds & elbows, but use an OEM gasket. I used the Barr kit on the last job because I had to finally convert from the OMC batwings on the V6 to the later 2 piece style, I used the Barr gaskets coated with Permatex Aviation, and no leaks. The Barr gaskets are very similar to the Merc silver gaskets.
If it didn't come with good gaskets, I would have used Volvo OEM gaskets, and the sealer they advise in their instructions.
The other thing is before installing the elbows, make sure that the bolts will thread all the way in, or else you might not get full or even torque on them, I'd use a thread chaser for that.
When the next change is due, I might try to adapt the Mercruiser dry joint style to my OMC engine, I could use the Barr kit for this, the thing is while the angles of the elbow exit are the same (7*) that doesn't mean that everything will line up. Might talk to a local shop and see if I can borrow a used set, just to see. That's one of Merc's better ideas for sure.
If you do a lot of your own work, that borescope camera is really useful, a real time saver.
I got one of those endoscope camera and esp for I/Os used in salt water they are real time savers. Today I used it to scope the water intakes of the Cobra drive where I have had an issue with barnacles growing there in the past. Found a little growth easily removed with a coat hanger wire. I’m...
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I used it to scope the manifolds and also the water passages in the outdrive, had some barnacles growing in there....
Since I did my top end overhaul back in 2017 I’ve been doing oil analyses and compression tests just to see if there are problems developing. Oil analyses have improved over time and this years compression test was the same as last years, 160-165 in all 6 cyls. I think it’s a good habit because...
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here there are a few pix of the inside of the elbows....one was totally clean the other had a bit of rust but I think that is from condensation, the exhaust on this engine runs really cool at idle and that side is the cooler of the 2. Like 85-95* at idle, barely warm.