Here in Cali, I've been enjoying my Personal Water Craft (PWC) aka Jet Ski's every chance I get at the local beaches, but I just noticed on my 09 that the stamped steel differential cover looks very rusted out with any factory paint mostly pealed/flaked away and heavy corrosion of the metal (coarse rust flakes, not fine surface rust). The axle housing itself isn't too bad, but there's definitely rust.

I was thinking of replacing the cover with an aftermarket aluminum one (Mag-Hytec comes to mind) but was wondering if there was anyone with aluminum covers that have immersed them "routinely" in salt/sea water for loading/unloading boats/PWC's, and if so, how are they holding up corrosion wise?

I would assume the aluminum would exhibit the typical powdery white corrosion in no time under these conditions.

The Mag-Hytec would seem to hold up better since only the flat surface of the fins are exposed while the rest of the body is painted.

If aluminum is not the way to go for sea/salt water application, then I just may have a stock/steel cover powder coated instead.

 

After you put it on, get some duplicolor clear coat and spray over it.

 

Mag Hytechs are powder coated black....idk about the aluminum fins but they can be painted with more clear coats.....make sure to use flat washers on the bolts also, it will will keep the bolt from maring the coated surface....

Your call on what you want to do

 

Those are good recommendations which so far have swayed me to go with the aluminum...

 

I'm assuming you are flushing the jet ski after salt water use. Why don't you hose the truck and trailer after doing that? That's the best protection you're going to get.

 

I generally did the truck, but never really aimed at the axle differential cover...

 

I just hit it once in a while with some black ruststop spray paint!

 

Aluminum doesn't rust. Everything else under your truck will. So will the bolts holding the cover on unless stainless.