Catalysts getting hot enough to smoke ought to be changed. It sounds as if over temp exhaust caused it. That much heat can cause the internal cats themselves to change, or it could change the shape or metal of the external cases.
I'm glad you were well treated. Boats cost a lot of money, they have warranties for the things that happen while covered.
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1989 Baja Sunsport 196, Mercruiser 5.7, For Sale
1987 Formula 223 LS with 1997 350 Mag 
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