I have a Next Generation (NextGen) 3.5 KW generator on BlueJacket. It has
an exhaust mixing elbow that combines the raw cooling water with the
exhaust and that flows into the muffler. You can see a picture of it at
http://www.geoffschultz.org/Ebay/Exhaust_Elbow.jpg

In theory this works well, but in practice, there are some severe problems.
The elbow develops internal leaks and raw cooling water can drip back into
the engine. I've been through 3 elbows and had to rebuild the engine once
due to a leak. I met other boats who have the same problems.

My plan is to replace the existing mixing elbow with a dry stack.
Basically I'll cut off the big round can and replace it with a 10" high
stainless tube U that will have the raw water entering 1/2 down the side
that connects to the muffler. I'll wrap the whole thing in insulation to
reduce the burn potential and heat.

Does this sound like a reasonable solution to this problem?

-- Geoff