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thanks for the replies. The motor had been converted to a long shaft before I bought it. the two piece lower housing is installed. It does fit kind of loose at the top and bubbles come out at idle. I stuffed duct seal in and around this joint the other day and it did no reduce the noise at all.
When looking down at the rubber expansion hose, it looks fine. when i had the rear cover off it looked fine, but i wasn’t looking for anything back then, just changing the water pump. the noise does seem to come from that outlet. There are two small, 1/4″ holes below the main outlet. I put my hand over those and there was no change in sound. it is slightly quieter when the water starts coming out, but like glass packs on a car engine, it really barks when you give it throttle.
the upper cover is doing a great job blocking the intake and general engine noises.
I will be taking the boat out soon and putting the 25 back on. If there is anything that you would suggest i do before for testing or after for investigation thank you in advance for any help.