I don't know what I possibly could have done to deserve what this engine
has put me through
In the 6 years I have owned it, EVERY single
season it puts me in knots.
Year 1-Overheating due to previous owner running with impeller blades stuck in pump elbow
. Also HX salting up restricting flow. Heat exchanger
had 2 pin holes and I brazed them closed.
Year 2-Filter clogged from ingesting engine
and broke. The wire mesh got stuck in cylinder 3 exhaust
valve and ruined it. Had valve seats recut and injectors cleaned.
Year 3-Exhaust elbow
broke, machined a new flange and TIG welded it back on.
Year 4-Developed severe overheating
and all coolant
was being pumped out of exhaust
manifold to overflow tank. Turns out head
was warped from year 1 and bleeding to coolant
jacket between cyls 2-3. Had head
shaved and magnafluxed, new head gasket
. Lots of fun diagnosis in bad areas with rocks with no engine
Also Year 4, lost
the starter the day before the Figawi race
and went through massive heroics to swap it out on a mooring
at midnight blowing 30 with a headlamp and minimal tools
Year 5-Leaking water pump
almost sank me on long motor
. Fortunately I caught it and repaired.
Year 6 (now)-Engine started and ran fine. Owning a Westerbeke
has taught me to always question anything and I noticed that the coolant overflow had dropped a bit. I pressure tested the cooling
system with my Stant tool and sure enough it was leaking down over time. Not quickly but 2-3 psi over 5 min.
I isolated the HX and pressure tested just that component and sure enough I could hear it leaking. Removed and disassembled it on the bench. When I removed 2 day old zinc I had just installed, it came out broken. Thought that was odd. When I took off end caps, it became clear. Found 3 more broken zincs laying in there. What I surmise is that they were binding up and breaking immediately upon installation
and I had no anode protection at all.
Anyways, thanks for listening to me vent
I called up Lenco in NY and they are making me a new HX today. About the nicest people to deal with and they were very helpful. He suggested I stick with copper (which was stock) instead of cupro nickel and we went back and forth. The difference in price
was $40 and I decided I'd rather overdo it but he said cupro nickel is oversold my the internet
To test the HX I machined up some brass plugs and hose clamped off the raw water
side. Used 1/4" NPT fittings with gauge and valve to put 15 psi into HX.