28/01/2018
Just a few pictures on a Big Job I have been doing. I was kicking myself that I never got any pics from when it was first started,!you should see the extent of the damage from a couple the pictures I did take even with a little work already done to scrape the layers of rust off. I had put a fair bit of work into the job when I remembered to get the pictures. I Will keep updating as it progresses.
The job at hand is basically just a refresh, though the damage is quite extensive.
It is a 71 Series Detroit Diesel 2 Stroke RA Model, With the Big Blower on the Port side.
It is in an old MonoHull Timber Boat, roughly 30-35 foot long. The Vessel was built & used for Charter runs and over the next few years had done a few Charters all around Sydney’s Waterways. It was then sold to a guy who really had no idea about owning a boat, at least not of this size. As this guy did not know of boats in this type of environment, he had went and started buying replacement parts and upgrades over the years through eBay and had them parts fitted. After the next few years the Cancer had set in and by this time it was quite extreme, when things went downhill he sold the Vessel to the Owner which I am doing the work for. The previous owner had mentioned to the new owner of the parts he had put in through eBay.
The Current owner has had to go right through the entire Vessel Removing & Replace all the eBay (JUNK) & had it all upgraded to the proper equipment for the Application within it’s current Environment.
The Owner knew he had to get the Most Important Part of the Vessel taken care of after so many years of Neglect. I had received a call from the owner asking to come see the boat and put forward my recommendations towards the badly battered and bruised Cancer Ridden Heart & Soul of this old Vessel. Upon meeting with the owner I was dump founded to the Extent this Beautiful Engine was sitting in. Like a doctor I said I will give it a try to see if we can cure the current Cancer and all the broken bones. I spent the next few hours going through the Engine Bay crawling over all kinds of broken pipes, Rusting metals, Sludge and Oil, it was horrible!! I thought I was going to grow a second set of arms and then I’d have to charge him Double the Hourly Rate.
I worked out a few ideas in my head and on paper for a way to tackle the job. The owner was very happy with my recommended Repairs and the go ahead was given and just the short version is basically as follows,
Remove ALL Hose clamps and replace with 316.
Remove all Exhaust and rebuild new Exhaust.
Remove all Accessories for Preparations. Then,
Taking Everything back to bare metal and wire wheeling, die grinding, Sanding etc... Replacing 90% of the bolts which are rusted away some don’t even have a head on anymore to grip onto to undo, and many that do have the heads still are either really rounded and furthermore snapping off, so it is very time consuming work.
I have the majority of it pulled down now. Just have to remove the Blower and then strip it down for rebuild as the Seals are weeping which is creating build up of carbon Deposits etc. then being forced induction are like a sand blaster being forced into the combustion chambers, so this has to be rectified before further damage to cylinders and pistons etc...
Then replacing any other parts that are needed along the way and possibly making all New Gaskets wherever they can’t be obtained quickly.
Prepare all Components to be rust converted and then Primed and Painted (just the quick explanation mind you lol).
Once all is dried from paint we will begin assembling the Engine.
Replacing all Fluids and Filters etc.
Once happy with the Re-assembly we will route all wiring and hoses neatly and secure them appropriately.
When all is agreed to be finished we will then, run up engine and make any necessary adjustments, checking for any signs of leaks, fix anything found, when happy that Engine is ready for work we will then spend the next few hours up and down the River before heading out to Sea, if all goes well, we will take the boat and head back to the docks and then do a final COMPLETE Inspection, any further adjustments and repairs will be done and the job will then be signed off and that will complete the job.
NOTE,
The Cause of all this work was that the Salt Water had Rusted through most components and even to the point that the Stainless Steel Hose Clamps had rusted right through and as they are under pressure they had got to a point then snapped!!! So I had managed to talk to the owner and explained to him that this all needed to be done right and it will be expensive, cost wise will basically mean a blank cheque. There will be ALOT of Man Hours and ALOT of Parts Required, and the full extent of damages we WILL NOT KNOW how far into it we have to got to be sure it is all Contained until it is stripped apart. (Never easy to absorb for a customer) He understood and gave the go ahead to start the job.
To do this job Properly, we will be using NOTHING BUT (316)STAINLESS STEEL!! Which is what it should have had right from the start and all the way through.
Not 316 bolts but still use the plain zinc coated washer or what ever it used to have.
(316 bolt, 316 Spring Washer and 316 Flat Washer!! )
The Hose Clamps when you buy them MUST be a 316 Clamp WITH a 316 BOLT and 316 NUT and even 316 Guides!!!
The entire Clamp must be 316.
I will get some pictures of Clamps so you can see the results if you don’t listen to this, providing I have not thrown them out.
This Engine has been Marinised from an on Highway Spec’d Application.
For the most part the Marinisation was done right with a heat exchanger etc, though over the years people were fitting cheap/rubbish Components/Parts to the engine and its Accessories which were made up of the wrong metals for this application.
So Be Mindfull If This Is You Doing The Same!! This IS what you WILL see!!!
Once it starts it is very very hard to contain.
316 Stainless Above Waterline.
Brass for Below Waterline.
Some parts have had to be sent to an Engineer for machining and repairs as they were too far gone for me to fix without the use of any machinery which I don’t and can’t carry in a Van.
People here this,
This is Thousands of dollars worth of work so far, we are not quite half way yet though not too far off. I have done my best to warn all my followers.
If you own a boat then this information, if (done right) will save you a lot of money in the long run.
Don’t cheap out on your parts and DO NOT NEGLECT YOUR ENGINES!!! They are the “Heart and Soul” of your Vessels. This guy may not of made it back from Sea on his next run out had he not of Decided to do the work which we are doing now.
Critical Heater Hoses to keep the engine cool were not clamped down and just hanging on due to rust completely eaten through snapping the Securing Bolt of the Hose Clamp etc..
Look I could go on for hours with this one, but this is enough.
Regards,
Light N Heavy Vehicle Repairs
P.s.
I must have scooped up around 3 - 4 20ltr buckets of Chunked Rust underneath the engine and gearbox, where you can see I have put the blue tarps prior to starting. Some of the Rust was actual sheets of rust a bit bigger then my hand. All piled up from falling off under its own weight over the years it was Neglected.
Don’t let this be you!!!!
Otherwise Ph. 0448934650, and have a blank Cheque signed and dated.
Light N Heavy Vehicle Repairs
