Muffler Noise Increasing Problem
I had a similar problem with my 1987 Catalina 30's Universal 21 hp diesel's muffler three years ago after about 600 engine hours. I eventually found that I had a hairline crack in the fiberglass wet muffler. The crack was where the exhaust pipe feeds into the muffler. Catalina had exact fit replacement mufflers in stock, so I ordered one through my boatyard, Riverfront Yacht Services, and at the same time they suggested I replace the stock cast iron pipe from the exhaust with a flexible stainless steel wrapped rubber exhaust hose designed for diesel trucks. That in turn was wrapped with a cream colored insulating fabric. The root cause of the crack was the vibration from the engine transmitted through the rigid cast iron exhaust pipe. I think the boat now has a far superior exhaust system than when the it was new. It is quieter, the exhaust pipe gives off much less heat, and it looks better. Engine vibration transmitted to the muffler has dropped significantly. Riverfront told me that they had done this type of upgrade/repair many times before and said it should last up to 10,000 engine hours. I believe them. I am now at 900 engine hours and there are zero problems. The yard did all of the work. Parts and labor cost me around $700 if I remember correctly.