The port riser showerhead was a bit easier to weld up than the starboard riser since it doesn’t have that sharp mandrel bend just before the showerhead can. Still, it took pretty much a whole day to cut all the holes, fit the water inlet and overflow pipe, purge, and get the welding done.
Cutting the hole takes less than ten seconds. Cleaning up the hole takes another minute or two. I don’t need a plasma cutter all the time, but it’s great to have one around! What a time saver!
Next I have to take the risers to the boat and do a final test fit. I still need to add a tab to the showerhead so I can attach a support arm; I don’t want all of that weight hanging off the turbo flange without additional support. Then I’ll insulate the riser with a combination of ceramic fiber blanket, which is good for continuous exposure to 2,600°F, then a layer of Inferno Wrap to hold that tightly in place, topped with fiberglass coated with high temp epoxy. I have a bottle of white epoxy colorant, which would look nice when the riser is new. I suspect it will brown a bit on the exhaust flange end once the engines run for a bit. All of the other hardshell risers I’ve seen are black, presumably because it hides any discoloration. Feel free to comment below about black/white preferences.