The Biggest Project I've Ever Tackled (Boat 454 Repair)
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- เผยแพร่เมื่อ 29 ก.ย. 2024
- One final deep-dive into my Chris Craft's 454 engines.
Pulling the camshaft and replacing everything I can.
This is my biggest project EVER. Topping out over 300gb of raw footage. I'm glad its finally ready to watch!
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I have worked on cars and engines for nearly 40 years, it was impressive to watch you make this repair with nearly no knowledge and you accomplished this with so much determination and drive. Very inspiring, great job.
This means a lot! Thank you for understanding where I'm coming from and enjoying the video. Now I know so much more about these engines, and can't wait to go even deeper.
@@CullenCraft ohh don't wish that on yourself my friend, remember things with little anchors on them get expensive..lol... but admire the confidence
I've been a ASE certified professional auto tech for so long it was called NIASE back then , I just want to say you did a fine job ,i really enjoyed your video and I wish you all the luck you need in your boating adventures !!
@@CullenCraft :)
You said it better than I could have. I come from a similar background and felt a sense of big brotherly pride watching him struggle and figure it out. Good job, Sir!
As a mechanic. You have gotten bitten by the wrench and grease bug. You are now a auto mechanic enthusiast. Great job for sure.
Thank you!
In 2002 I was on a camping trip with my wife and son he was only eight years old then. I was hauling a trailer full of camping gear behind my 1995 Toyota T100 pickup truck which had a six-cylinder engine. My harmonic balancer went out and my engine light came on. The first mechanic tried to work on it but told me I needed to take it somewhere else. He didn't know how to fix it. So we went to an auto parts store for a recommendation. We took the truck there. The mechanic knew we were in a very tuff situation so he took advantage of me big time. The final cost to fix it was twenty-three hundred $$$$. I was very unhappy but paid him and it ruined our vacation. You just replaced yours for a fraction of what ours cost. Your a very smart young man and most people can't
work on engines. You're very gifted!!
I've been screwed over by a few mechanics myself. My first ever "breakdown" cost me $700... For what turned out to be an empty tank of gas! That's why I work on my own stuff now. If I don't know something, I can learn it, and be more prepared for the future.
Cullen, I am 73 years old, been doing this type of work over the years since I was 16. You amaze me and make me proud. Great to see a young person with his "shit:" together in today's world.
Thanks! I try my best haha.
Congratulation, you deserve a big round of applause. I've been exactly where you've been. I also felt you elation when you finished the job. Great job. Looking forward to your next video.
Great for you man. The can-do attitude is EVERYTHING. I was a mechanic years ago and this is not for the faint of heart. Of course I would have done some things diff, but you did great!! Keep it up.
:D
Bravo mate. Taking this on took more courage than I will ever have in dealing with mechanical things. The engine sounded sweet. Obviously having watched the previous videos you are close to getting the boat with no name to plaining across the water. The silent hours working and hard work has paid off. I'm looking forward to next Saturday.
😁
Great job! and I love the music you created with putting all the little parts push rods, so cool and creative!
This video is so satisfying. I love seeing and hearing these big blocks.
great to see...you are learning how I learned working on engines 40+ years ago...just DO IT, and yes, READ the manuals as well...and NEVER be scared to have a go!!
Never learn if you never try. Thanks for the support!
Just a heads up when you put the new camshaft back in. And the two dots the one on the cam gear and the one on the crankshaft are pointing to each other like when you removed it, the number six cylinder is in the firing position not number one. If you noticed when you took it apart the dot was on top. I am going to assume that you had the rotor pointing at number one on the distributor cap when you remove the distributor. So after you put everything back in and have the two dots together rotate the engine one revolution so the dot is on top. Then when you put your intake manifold on and put the distributor in it will be all set. I can’t tell you how many people think that when the two dots are together number one is firing. You’ll probably get a lot of argument on this but I’m telling you that’s the way it is. It’s also this way a Pontiac Oldsmobile and a lot of other engines. Buick being an exception. But we won’t get into that right now. Again make sure that dart is straight up on top and that the dark on the crankshaft gear is up on top put the distributor in pointing it to number one on the cab and you’ll be close for timing
I may not have made myself clear. It’s all the trash from the first camshaft that you need to worry about. That’s circulating through the engine and maybe affecting your oil pump and main crankshaft bearings.After you’re finished maybe you should check and keep an eye on your oil pressure. Maybe invest in an oil pressure an alarm. You should have at least 20 pounds of oil pressure at 800 RPM. PS your boat looks great
I have a 1979 Pacemaker Sport Fisherman that I live aboard (33').. I'm just now struggling with a 454 that broke a piston (it was sold as a new rebuild, I put 20 hours on it and it broke a rod at idle at the dock (the only lucky thing about it...).. So I'm now pricing out new engines and sorting out how to do this swap.. I see that your deck was removed.. So I have to see if mine will do the same. I'm not sure that the small dual access hatches will allow for engine removal.. So this was a great video to see! Best of luck and smooth sailing!
Deck was removed? I don't know what you mean?
@@CullenCraft The deck (floor) in your salon (covering the engines). I am assuming that you unscrewed the decking to gain access to the engines
Oh, the Sole! Yeah, mine lifts up. No screws.
Thanks for your videos, I did the same thing to the 396 Chevrolet big block. I wanted to replace the water pump at the same time, I did not do it. Less than 300 miles the water pump went out.
Oh gee. Guess I should look into that. I replaced the raw water impellers about 8 months ago.
Teflon tape on the manifold water fittings would be good to use to prevent leaks.
Valvoline zr1 high zinc racing oil from o'riley is what I use in my rebuilt crusader engine recommended by the engine shop.
Heads , cam and intake . Rollers work with the cam . Rollers free up a lot of friction = MORE POWER .
I'm truly happy for you. Not only because you got it to work. It's the confidence you are gaining! Things in life are not easy or handed to us. If we
Think about what needs to be done and believe in ourselves man is unstoppable!
Dude, you are amazing. I could not look away for a minute!
Congrats Cullen on getting her done! I will admit that I cringed a little bit when you fired her up before changing out the old oil and filter that had the metal particles from the damaged camshaft lobes and lifter. Also as an aside if you end up doing the other motor, they make a handle that bolts onto the end of the camshaft for better control taking out and putting them in. Glad you got her running again!
That engine sounded amazing when you finally got it started. Very smooth.
vvvVVVROOM!
Congrats. This is very impressive work. I was glued to the whole thing with probably the same level of anxiousness. I am so glad Murphys law didn't prove to be true. So many things that can go wrong when you open up such an old engine. I wonder what happened to the old camshaft? Engines dont typically wear out so badly. Hope no oil passages are blocked and such. Keeping my fingers crossed this rebuilt engine serves you for years to come. Cheers!
Thanks! If it doesn't, well maybe its time to get a pair of diesels in her. I hope these are able to stay in service for a very long time.
As a mechanic, I can say you did a great job. Can’t wait to see it cruising!
Thanks! Me too!
Woohoo Cullen.
Can you feel it.
You’re so close to being done eh
Zzz
Lol
Man, I'm partying with ya! Great job!!!
Pfft, you're doing great . . . way better than some "mechanics" I know.
Keep asking and investigating every time you don't understand something.
That's the right way. Good luck and best of wishes. 👌😎👍
Well done Grasshopper....
Awesome job mate! Massive achievement for a newbie your confidence will keep improving on every job. Motor sounds sweet 👍
Yeah I was gonna say after a heat cycle you have to retorque the exhaust bolts.
Hey Cullen, what was more exciting, that first boat ride on the St John’s, or getting that engine back together? Great Job!🛥🛥
The first cruise for sure. This is just a stepping stone to get her back out there!
Very Impressive! I have to change out the exhaust manifolds on my 454 Chris Crafts as well. As you mentioned, the Chris Craft manifolds are no longer available - so I will be using the Crusader style as well. The CC manifolds had a 3.5 inch dump and the Crusader elbows are only available as a 3 or 4 inch dump. It looks like you have a bushing or a piece of 3 inch exhaust hose used as a bushing on the 3 inch dump. Not a bad idea versus a reducer. Let us know how it worked! Manifolds stay cool?
Peak out at 180. Perfect temp!
We can do anything with the help of TH-cam and the right tools, can't we? 👍👍👍👍
Absolutely well done it’s nice to see somebody doing this type of work for themselves 👍
Glad its done!
Great job! I do have one question. From the video it looked like you used home silicon based caluk on your intake manafold? The same type you use in a bathroom?
Double roller chain somebody's been in there
Well done!
You do not need to soak lifters. Make sure to use copious amounts of break in live on those lobes!!! And the feet of the lifters!!!
Great job dude you have a lot to be proud of!
You might want to re torque all the nuts and bolts after you have run the engine for a few hours as all the gaskets will compress up with use and the nuts and bolts will loosen a fraction .Great video by the way.Keep up the good work .
You should have changed the camshaft bearings also
You should do charters for hire with this boat 🚢🤔👀😊😀. You have a cool place to hang out 😊
Lol a charter license is expensive and you need special insurance. I'll keep it as my house.
@@CullenCraft If I were on the same marina, I'd send you some complimentary beer 🍺 👍
You never checked to see if the piston run to tdc on all 8 . Good luck I hope no damage was done
Fuck
His name is Cullen?
Why did he not say this one day one. Now Cullen craft makes sence. Ontario Canada
Hahaha I'm still trying to figure out the intro. I think this one will stick.
Awsome job!
Great edit.,.
Thanks!
You did align the the 2 dots on the timing gears ?
Good job!
Thank you!
Wow....Excellent job sir! People always say, boat is a money pit. Well, just as everything man made is but with boats, it's the labor that costs double, triple and sometimes quadruple! Keep doing these maintenance repairs yourself...remember, boat mechanics or any mechanics have the knowledge...that's what separates them from us, but these days, TH-cam videos, readily available internet articles and how to guides, it's nothing to it! Again, very impressive, please keep up the vids, it makes us all want to be you and with you while you're doing all that. Just for shits n giggles, did you call around to price that repair for labor only? Oh and BTW, do you know how much they would charge you for the parts if the mechanic bought/brought with him/her?!?!?!?! hahahahah Lastly, the only thing you could've or should've done as a precaution "while there" is replace the front main crank seal. Very cheap, very easy and would be peace of mind for years to come. Again, EXCELLENT work....
I can't imagine how expensive that would be haha. Too much, for sure.
Question where you buy all the parts I just got a 1975 trojan. Tht I am having hard time to find parts for chrysler 440
I buy the parts where they are the most ubiquitous. Obviously, a lot of boat-specific parts will be hard to find, but I bet you can find a Chrysler flathead gasket at AutoZone.
Always look for the lowest common denominator, if it seems like a car part, ask the car suppliers. I was able to track down several Chevy suppliers in my area and asked for quotes to find the best deal on the camshaft.
Appreciate I been watching you videos over over I am learning from you videos !!
My best advice is don't be scared of your engines. Especially if they're based on common enthusiast motors! Just go into O'Reilly with questions about your "Chrysler Imperial." You'll get a lot more useful info.
I remember a few years ago I asked specifically about a Chris Craft Corinthian and they pulled up my own video on the store computer lol
great job!
Good for you.
Congratulations
Job Well Done.
Great job!! Very inspiring!! Thank you for sharing! :-) Got a Chrysler Hemi V8 marine engine ahead .. will be interesting, too.. ;-)
Haha good luck! You've got this.
oil with zinc avail. valvoline racing oil..
Yes. VR1 10W30 for it.
Got a question where did you order your parts from funny thing is I’m doing the same motor in the same boat but mine whole boat has a lot to go before it’s as nice as your.
I found a local parts distributor that had the right parts. It's the same cam and lifters as a standard 454
@@CullenCraft thank you very much we can’t wait to have are boat looking as good as yours we are also doing a few major upgrades to ares I see you have a after market fridge in your also is it a standard 110 or is it still a 12v we are gonna be full time on a mooring ball but my fridge took a turn an needs to be replaced.
One other thing I’m having issues with my STB motor it doesn’t want to fire which I’m pretty sure it’s a reverse motor since it’s turning to the right what firing order are you running ?
@@ValhallaChriscraft firing order should be cast into the air intake manifold. Easily visible numbers 1-8 above each cylinder.
@@CullenCraft it is just wanted to make sure that’s the one you used I’m changing my mercruiser IV electronic ignition out for a ACCEL hei at the moment.
Hi, which type motoroil I must should use,1990 454 Cruader ? 😊
General advice is Shell Rotella 15w-40 with one bottle of Lucas zinc additive per engine
@@CullenCraft thank you very much 😊😊😊
THEY DO SELL CONSUMER GRADE OIL WITH ZINC!!!! I use AMSOIL's Marine grade diesel motor oil (Don't worry about it saying diesel, it works the same for gas engines) in my 1970 Chris Craft 307's. because my engines also have flat tappet cams and need a lot of zinc..The oil is absolutely amazing and has some of the highest amounts of Zinc and other additives great for the marine environment you can get in a motor oil before you get into the real specialty stuff. LOL hope this is one of the comments you end up reading! www.amsoil.com/p/sae-15w-40-heavy-duty-diesel-and-marine-oil-ame/?code=AMEQT-EA#pills-home_0
We bought a 1979 Gulfstar trawler with a frozen engine. After getting quotes of 35K $ to replace it we went to work. We swapped out an engine and gave both engines an overhaul. I have the same level of knowledge as yourself. The day I got both engines running simultaneously is a day I won't forget. I could feel your satisfaction. Great videos. Keep them coming. Sean
Thats an awesome story! I bet you've had some amazing adventures since that day.
@@CullenCraft we have had tremendous adventures with her in the last 4 years since we own her. Having bought her in New York we sailed down the ICW over two summers to Florida and then to the Bahamas. We shipped her to Italy in the back of a ship and now keep her in the Mediterranean.
Wow! I'm jealous!
@@CullenCraft Im lucky the lady in my life loves boating. It makes it so easy. Our boat looks very similar to your boat. Our engines are diesel.
Hi Sean, how did the importing of your boat to Italy or somewhere in the EU go, was it easy to ship the boat? Once you got it there, did you have to do anything regarding the recreational craft directive (RCD)? Also, what diesels did you replace the petrols with (your boat must be worth quite a bit more now)?
It's not supposed to be blue blue is for the color orange is Chevy color 454 is a Chevy motor
GOOD JOB
Good luck! Make sure you learn a lot before starting off.
They are excellent marine engines .
Was a marine mechanic since 1979 to 93. Salt water.
Chrysler held up the best.
Cullen, you might contact Car Wizard on You Tube he is a master mechanic and can work on anything. He just bought a thirty-three-foot cabin Cruzer and has been doing the same things to his boat as you are doing to yours. I love your positive can-do way of thinking. Thanks for another great video and God Bless you always!
Great Job. Hope that was high temp silicone. It looked like household window and door trim silicon.
I had the same thought
I thought the same thing. That should have been RTV
I saw that caulking gun of residential silicone come out and said OH NO!
I'm very impressed he was able to do this on his own but I think you folks are right and I hope he reads this because that silicone will cause all kinds of problems shortly
Has it started leaking oil yet?
Just a quick stop back through. Good to see you working hard, learning, and taking good advice from many people. Here is my latest offering if it helps... always make sure that you know what tools that you will need before you start a job. On the timing gear puller and other common tools - both Oreilly's and auto-zone offer good loan a tool programs for common tools. The lower timing gear puller gear puller is available, just leave a deposit, which you get back when you bring the tool back... best of luck and I will check back again. :)
Cummins engines still have flat tappets in the Ram trucks - I run diesel oil in my boats for a reason! :)
Yep, diesel oil still has some zinc for the flat tappets engines.
Run 15/40 diesel oil, along with STP for more added zinc.
Can you run diesel oil in most any conventional engine? As long as it's the right weight?
@@johnnyohness6610 I've run it even when it was close. 15w-40 in a motor calling for 10w-40 for instance.
Penngrade 1 is the best for flat tappet engines. They’re starting to take zinc out of diesel oil.
Do all Mercury engines 454s have flat tappets?
Now that's an achievement, great work! I couldn't imagine having this project in my living room, it would make me crazy to not be finished lol! Totally feel you on those all-nighters though, may not be good for the body but it's good for the soul :D Congratulations dude, I am super curious to hear how she handles now.
Did you do a compression test before Taking the engine apart?
That dished out lifter would show on a vacuum guage as a jumping needle on the gauge. You should just take both heads off and do a valve job on them.
You remind me of the days I did all the work on my 88 Carver 38ft aft cabin. Twin 454 mercs....7.5 Kohler genny ......3 heat pumps etc and all worked great...never paid anyone to fix anything. You will never regret doing the work yourself as you will know when your CC is running correctly and pocket the savings. Buy new carpeting as a reward. Good Luck!
Well it sounded good, I’d pull out the spark plugs in 20hrs and see if they are all burning normal
Very impressive. I’ve been thru this a few times and know the feeling is nothing like it. Especially when I’m sure you’ve had people tell you how crazy you are lol
Well at least the wife can't get mad at you for working on the engine in the middle of the living room. 🤔
Cullen. Dave a Certified MerCruiser mechanic here. The problem you’re going to have is the shavings that came off of the camshaft in the valve lifters. It’s called trash. That’s all inside the oil pan. You really should pull the motor drop the pan and clean out all the trash and install a new oil pump. Second best is if you can get a drain pan under the oil pan drain the oil real good put fresh oil start it for a few minutes drain it again changing the Oil filter each time. Still that engine has run with trash inside.
Reliability may be a factor.
PS I really didn’t make myself clear. The trash from the old camshaft with the engine running. After you get a broken in and cleaned out the best you can I would watch the oil pressure especially at idle. I believe the specs are 20 lbs at 800 RPM For a 454.
@@davieddt That oil pan really needed to come off, many older boat motors have a half rotted oil pans anyway from people letting water sit in the bilge and rusting the pan. If I find any pitting in an oil pans metal, I replace it. Also, any repair that requires a bearing, piston, lifter, pushrod or cam due to damage, one of the most important things you can replace is the oil pump as has been stated above. This eliminates oil pump failure, if that caused the initial damage, from destroying the rest of your engine. I always buy the best oil pump I can get my hands on as well.
There is probably a quarter of an inch of metal bearing sludge in the bottom of that oil pan. Fresh oil and a long run of the engine at cruise rpm and that sludge will begin to break up and you will have metal shavings in your oil galleries pumping through the engine... Joe
Just bought a 43 foot trawler a week ago. All my friends think I'm crazy. Discovered your video's just today, will point all my friends to your channel, and they will immediately understand why boating is such a different live style. Happy sailing and keep on going with your dream.
Living the dream! Make and year?
@@CullenCraft I', m almost too embarrassed to say, it's a 2003 Northavn 43 boat. Why I'm embarrassed I just bought it but you with your passion would deserve it. Love how you express yourself. Greetings from Germany.
Wow! She's a beauty. Treat her well and thanks for watching!
That was awesome, you should be so proud of yourself👍The engine sounds great, can’t wait for the sea trial😎🇨🇦
I like your “get it done” attitude.
Sometimes you just gotta get it done what can I say? Lol
Great job, Cullen. I love your enthusiasm and determination. You took a risk, stepped outside your comfort zone and it paid off. I'm not sure who said it, but remember this: "You can't steal second with your foot on first." Keep coming with your videos.
Enjoyed the video. It might sound silly to some but when you work on your own engines there is a bond that develops between man and machine that only we understand.
Keep at least a complete set of rockers, pushrod and parts, for 4 cylinders, in case you're at sea and your ability to get back home depends on replacing parts.
This is a good idea. Thanks!
The rusty port could also be a head gasket problem.
Dude, amazing! My hat's off to you! Takes some cojones to do what you did, and what you are doing!
you've tore into the engine way deep.
but you haven't mentioned that you looked at the cam bearings.
I've heard they last a loong time
Both Chris-Craft and Crusader engines were painted blue when original.
Brilliant project, brilliant effort and brilliant video. Really is a stand out effort mate. I think it’s your seeming unbounded energy and enthusiasm that is most inspirational.
Best 35 minutes and 41 seconds this week! Finally you got it running!! Next test: top speed run? 😉
Really glad you liked it!
three hands leaves the fourth for smacking you for using channel locks on the puller nut
Hey I didn't have the right size wrench.... Plus the puller was a rental lol
Well done! I have been watching this boat video progress. You have shown what can be done with perseverance and self determination. I have shown these videos to my 17 year old son to inspire him. You remind me of myself at your age.
Gotta dream big and you can't be afraid to make mistakes along the way.
Nice job!! Don't know many DIY that could or would be able to perform those diag and repairs with success without some guidance. That was my only way to get on the water also and it has worked for 45yrs. Shows that with the right attitude and research methods your dream becomes reality!! Now that e everything's done it's just knots and lines...lol 👍
I'm a 36 yr diyer on cars... My 1st car was a 73' Pontiac Gran Prix with the smaller 400 cu. inch engine. The larger motor was a GM 455 (similiar to your 454's). It's very impressive that you undertook a major rebuild project by yourself and didn't allow the issue at hand dissuade u. GREAT JOB !!! And congratulations on your success - it just makes you appreciate your motors even more when you've done it yourself... Keep the videos coming Chris Craft made some great boats in that period.
Someday I want an old Pontiac like that. Great cars!
@@CullenCraft think GTO ...
www.mecum.com/lots/FL0119-359472/1967-pontiac-gto/
So, Cullen... you're in for good news... I have a 88 Cobalt Condesa w/454 B1 Drive system. There is a manufacturer of oil in the midwest, CENPECO that makes oil with a heavy Zinc and additive package designed specifically for older engines. This was recommended to me by the previous owner. Not certain what weight oil you use, however, I use the CENPECO 15w40. A google search will help you locate some. www.cen-pe-co.com/2019/index.php/products/oils/heavy-duty-engine-oils. NO, I am not a salesman for for them. Cheers.
What a JOB. You've accomplished something I would never attempted. Congrats! Tom Ireland
great job.... awesome! just think cleanand cool with your raw water cooling..freshwater flush or descale whenever you can
Rotella T4 15-40 is an excellent marine engine oil, great for flat tappet engines too. Consider Wix or Naps gold oil filters. Note! Make sure the old filter gasket isn’t left behind so you don’t double stack it and it bows out. I caught this before disaster on the Napa’s a few times.
Keep all the parts you're replacing as spares. Use diesel engine oil. It has plenty of zinc and you won't have to use an additive. MAKE SURE YOU RUN IN THE CAM CORRECTLY!!!
nice work brother! Im doing the same exact repair right now on my Crusader 454, I have a busted rocker arm and cannot track down the right part number for these. Which rocker arm did you use for Melling?????? Please help
Gosh, Cullen I could never figure out what you are doing. So much enthusiasm, makes me want to get into fixing things again. Marine mechanics are so expensive. I love the lay out of the Chris Craft Corinthian. I saw the video on the older guy who built the Corinthian. How exciting is that. I love the entrance to the aft cabin and spacious kitchen/family room area. I love my Bayliner but twin engines so much better.
A tip my Dad gave me and seems to work more often than not with hard to remove threaded items (IE rusted). If unscrewing does not move the fixture, try to move it in the same direction it last moved in. What that translates to is in a normal thread the last time it moved was to the right when getting tightened. IF you can move it a 1/32 of a inch, it will come our. Use care and patience to not twist it off.
These are not marine powers, these are chevy based block, 454 crusader engines. Genuine marine 454 crusader exhaust manifolds will fit, don't quote me here but I believe the design of the manifold changed in later years of manufacturing, these engines (once running of course) are some of the better easy to work on marine engines someone can buy, simple, cheap (by marine standards), parts readily available. Worked on dozens of sets, easy to tell its a crusader, someone may have done a shit paint job but from factory they were all blue as well
Hey buddy I really respect your efforts and success with your motors . To me I would always buy the best internal motor parts . Your cam and lifters ar Chinese junk Iam sure, A good quality camshaft start around $450 .
I think you did a fantastic job!! They may have been fine, but if you have the capability, changing out the water pump and fuel pump could save from having to change them out later. Mine were fine, but I changed them out anyway and kept the old ones just in case.
Replace 454 with 383 stroker engines the 454 have valve trans problems because the push rods are angled and the oil filter is separate from block and the cam moves forward and back so the cam bearings wear out fast and new lifters they don't make anymore only remanufactured you will need to replace cam bearings or you will have low oil pressure on the new cam
Use Delo 30 wt for diesel engines. And bottle of zinc additives with marvel mystery oil in fuel i use this on my big block marine engines
And customers engines i service plus always use AC Delco oil filters ot wix ... never use fram or anything else they can damage engines
Napa gold oil filters is made by wix filters ok to use also great video thanks for posting 😊
You definitely don't want exhaust manifolds leaking water back into the engine. I had that blow up a Mercuruiser chevy small block that was almost new. Expensive and no fun so always inspect your exhaust manifolds if you have them off.
Good job on the top end build! In the future tho I would suggest testing parts before you buy. I doubt you had a bad water jacket, and a simple pressure test would have told you all you need to know (aka you could have saved 400 bucks). The rust in the manifold was most likely due to outside moisture getting back to the engine and no exhaust to push it out and coat the inside of the exhaust with carbon/fuel/oil that is present during combustion (that cylinder was down due to cam wear).
Hey brother you need to invest in a 3/4 " Milwaukee Impact for your boat brother. You will use it for EVERYTHING.