Wakeboard tower cracks at mounting plates

I

Im_on_a_boat

New Member
Aug 5, 2010
10
Florida Panhandle
Boat Info
205 Sport
Engines
5.0 Mercruiser
I recently purchased a 2007 Sea Ray 205 Sport with just short of 200 hours. I've had the boat out about 6 times now and used the tower twice. While washing the boat the last time I took it out, I noticed a hair line crack approximately 1 inch long in the aft right side tower mounting plate. I checked the other side and there is a much smaller crack forming there as well.

I have a few guesses as to why it's cracking. I'm guessing vibration from getting bounced around during rough seas in the bay or maybe from vibration while trailering. Any thoughts? Has anyone had a similar issue?

My friend has a 2008 205 Sport and Sea Ray has changed the mounting method from a plate and 3 small bolts to one large bolt and no plate. I wonder if this is due to a common failure like mine?

I have emailed Sea Ray inquiring how they recommend I repair the cracks, but have not received any direction from them. I am certain it will need to be welded. Just looking for some helpful insight from the manufacturer.

I'll let everyone know how the repair goes.
 
Check the top edge of the tower (front and rear) for damage. The previous owner may have ran into or backed into something. I doubt pulling a skier would do that.
 
I think he bought the boat with 200 hours and he has only taken it out 6 times.
 
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Oh if that is the case the fact that the boat has only been out 6 times and the tower used twice is useless information, no? :huh:
 
I guess the important question to ask is: Is it posible the cracks have always been there and he just noticed or is he certain that they started to form on the last trip out (or last wash)?

I think that it would be pretty tough to stress the boat out enough to crack it just by wakeboarding. Now driving into or backing into an overhang could cause damage (don't ask how I know.. got lucky).
 
Has anybody pulled a tube from the tower? (Grin)
 
black magic said:
Check the top edge of the tower (front and rear) for damage. The previous owner may have ran into or backed into something. I doubt pulling a skier would do that.
Click to expand...

There's no damage to the tower anywhere, other than the cracks on the mounting plates of course. I'm pretty certain pulling a wakeboarder had nothing to do with the cracks. I have a feeling the cracks may have developed from hitting some rough water in the bay where I have run the boat. Just trying to find out if anyone else has experienced this before.

By the way, my apologies for not responding to these questions earlier. I have been away from my computer for a week and just now catching up.
 
First Born said:
Oh if that is the case the fact that the boat has only been out 6 times and the tower used twice is useless information, no? :huh:
Click to expand...

I guess it's all in how you interpret the information. Some general information regarding how much the boat has been used (200 hours on the boat) combined with the relatively few times (6) I have taken the boat out on the water in the last month. Of the 6 times I've only used the wakeboard tower once or twice.

How much use the boat has seen overall and since the cracks became visible would seem to be pertinent information. But, I see we disagree on that.
 
The larger crack is on the left side, the smaller on the right.
 

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WOW, is there any cracking in the Gel Coat? I haven't seen anything like that. I know that my tower flexes quite a bit in rough water when there is no load behind teh tower.
 
I've been in contact with Sea Ray and they are deferring to Xtreme (tower manufacturer) due to the warranty expiration. Xtreme is certain that I or the previous owner somehow misused the tower, although they can't explain what I must have done to damage the tower.

So, I'm replacing the lower halves of the tower and crossing my fingers that I am able to avoid the cracking again.

No visible cracking in the gel coat, so the damage seems to be limited to the tower.
 
If the manufacturer changed the design and they are putting the new design on the same style haul then chances are the design was bad.
I can tell you that these are stress cracks round the weld. Either the base material was not thick enough or the weld was not correct.

In the first picture you can see the failure at the weld then tailing out away from it in an arc. The weld in general is small and undersize for the stress it needs to handle. Also it appears that the cracks originate at the end of the weld bead or where the weld was allowed to puddle. These are stress points that are doomed to fail in time. This failure is a vibration failure not an impact failure. The material is clearly not pull'n away as it would be in and impact or over loading situation. The jagged edge is proof if this.

If there are any other certified fabricators out there with a different opinion please weight in. My opinion is just that.
 
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Poor weld in my opinion. Hopefully the manufacturer will do the right thing. Good luck! BTW, it's okay that you described the hours on the boat, how many hours you have used the boat and how many times you have used the wake tower. Some of us don't mind reading additional info, pertinent or not. Welcome to CSR!
 
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Thanks for your input, gentlemen. I would agree with your analysis on the cracking. But, unfortunately Xtreme disagrees. Sea Ray is offering me the replacement parts at cost, but that's it. My expense to include installation.

I ordered the parts through my local Sea Ray dealer last week. I'll let you all know the final results. Thanks again for your opinions.
 
Attach pictures of the new parts so we can see if they have improved or modified the weldment. If so, then that’s a sure sign of initial welding problem on the old part.

If they are different then I would send the picture to Xtreme and ask for clarification of the improvement. Don't back off until you get their final kiss off letter.

I think the dealer is taking the high road in offering you the replacement at cost. They could have stood behind Xtremes skirt and charged you list. IMHO.
 
I'm with Oldskool on this one, those welds are pretty lousy. I've been a certified TIG and MIG welder since 1986 and it always amazes me how some "reputable" manufacturers can put out product like that. They should feel lucky the tower didn't snap off and kill somebody. Good for your dealer to give their cost. Send your photos to Xtreme if you haven't already, they will at least know that you know the truth. Hopefully the next set is better, please post pics when you get them.
 
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