Stig,
First with respect to sumps rusting - that is just what happens with inboards in salt water.
I think it is mostly because the sump is close to where the salt deposits down in the engine well.
No biggy, by the time the sump has rusted to the point of needing replacement you probably need to pull the donk for maintenance anyways and can bolt a new sump on. For a lot of common blocks you can buy trick SS316 sumps which may help in the long run.
With respect to running a non marineised engine is salt - I would avoid if at all possible.
Either set up a heat exchanger or do not to do it!!!!
For most ski boat engine bays a heat exchanger will not pose too many problems space wise. You already have a raw water intake and water pump, just need to plumb in a water to water cooler and you are away.
Have fun
Steve

