My boat (and Bruce Martin's boat) are both 38' Commanders and we don't have an aft stateroom, so we didn't have that problem.
I took out everything from the motor to the collector, including the collector, and everything there was put back either new or in "as new" condition using high temp silicone tube (which, incidently, is MUCH MUCH easier to handle than the stiff rubber stuff) and new fasteners, etc.
I did not replace the rubber tube that ran from the collector to the muffler, as this did not appear to have any structural or other issues. The muffler is cast iron, and it may have a rust-out problem too, but so far no detectors have gone off and no smell internally. The cast iron is a lot longer lived than the galvanized steel collector, I am supposing.
You may have to remove interior panels to gain access if you are going to work back on the system. Since my collectors, as illustrated in the photos, were right there in the engine compartment, they were VERY easy to get to. Just loosen the fasteners and pull them out. The tough part is finding something to go back in the hole, in the way of a new collector or fabricated device in stainless.
As you can see, I used a 90-degree high temp fiberglass elbow to go back in the rubber tube where my collector came out, and Bruce used a stainless steel fabrication to go back. There is more than one solution, but the fewer the parts and joints, the fewer chances for a leak and/or other problem.
Hope this helps a bit?
Regards,
Paul
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