Well......Time got away from me.
I never pressure tested ANY of the parts. They sat on the garage floor all week, and I hastily put them back together on Thursday night. I did "clean" them with a little degreaser/alcohol on the way back in. Made sure all the interfaces were good and clean. Then made sure each connection had the band clamps a few degrees "out" from each out. The hope was to avoid the possibility of both clamps creating a "pinch" in the tube allowing a pressure leak to form. Got it all buttoned up, and quickly tossed the rear tray back in assuming I would be back in there in short order. Ran a small bead of silicone around the edges and that's it.
Not sure how many hours I put on it this weekend, but we were out Friday from 4pm to 8pm, Saturday from 11am to 6pm, Sunday from 10am to 5pm, and Monday from 12pm to 4pm. Ran almost a full tank a fuel through the boat. I'm going to guess around 10hrs of engine run time or so. No tubing was done, but there were several "top speed runs" on each day, and we pulled me around on the skate a bit on Sunday morning. Crossed the lake multiple times. Kids were on/off the swim platform playing a ton all 4 days. Water guns, jumping from the boat, diving contest, all kinds of stuff.
Bilge NEVER ran. Not once. Not a single time. Ski locker was dry all weekend (aside from wet stuff being stowed there), and never filled with bilge water
I pulled the plugs each day, on the ramp to ensure I was getting a good downhill "drain". Had a few gallons from each plug each day. But it was "cool" lake water, not heated engine water. I still have water getting in somewhere, but I'm betting it's that stupid crap-ass designed rear storage tray access panel. I know it's not sealed well at this point, and I'm sure that's where the water is coming in at this point. Still not really enough to worry about, but more than I like.
I checked the resonator with a mirror and flashlight when we got home yesterday. I don't see any signs of additional water spray on the resonator. That makes ZERO sense to me, since the flow it AWAY from that interface, and there really shouldn't be a ton of pressure on that connection. However, I don't have any other "smoking gun" evidence to point to.
Another interesting point, and I'm unsure why this might be the case, but the witness spray (the pisser.....I really hate that term) seemed to be MUCH stronger than before. It was certainly stronger at idle than it was previously, but even just in no wake mode I could HEAR the water coming out. I have no data to back that up, and it might be placebo effect there, but it sure "feels" like that has increased in pressure.
At any rate, I'm going to call this a win. Best I can tell it was the hose connection on the downstream (exhaust) side of the resonator that was the issue. I'll continue to monitor and report back as I get more run time on it.
FYI boat has 160hrs on it at this point.
Tagging
@YamahaziPilot for visibility.