Pressure testing and installing the repaired Vetus heat exchanger 

Great job in fixing what was essentially a trashed heat exchanger. No reason why that repair should not last many years. Just shows that with a bit of ingenuity most things can be fixed at low cost. Thanks for sharing this, you may well have saved quite a few boaters a heap of money down the track.

Nice job and funny to see that living on the opposite side of the world you still have the same Würth tools and chemicals as we do here!

@Dangar Marine. Still really enjoy the peaceful interlude with Daisy and Daffy at the end of your videos. Please keep it up! Thanks, Stu! Watching from Fairbanks.

Stu, Really enjoyed seeing a good old repair video. Having someone standing there watching every move tends to be a bit cringey and puts one off the normal routine, but he turned out to be a good sport and a decent helper. For sure, he will understand how much time even simple stuff takes. Looking forward to the next video.

Good fix Stu!! 99% of people that would have seen that would have just bought a new one. Keep us posted on how long it lasts!

What a shot! That coolant pour-in with no funnel!

Good for my mental state seeing a couple of guys working on the boat and having a beer.... I'll be starting a wreck hunting/history channel soon, first episode in my Dangar T shirt as you've inspired me and kept me going. .......A homemade sidescan sonar towfish would be a good episode Stu ;)

Holy shit! You own your own helicoil box of tricks!? You sir, are the most professional hack that I have ever come across in my time of adventuring with hacks.

Dragon u are a miracle work . I sure hope I can made my 2008 a electric start . It is a two stroke. Cheers Johnnie

i like this video 50 thumps up, what i like mostly about it, you went through the difficult part with your viewers incase we come across obstacles, thank Chief.

Just finished a similar job on my heat exchanger and I was shouting at the screen "YOU NEED A WASHER UNDER THE END BOLT"' sure enough you did I was quite smug until I realized I went through allot harder trials and tribulations with mine, and made some really dumb moves of my own. But mine works now and no doubt your mates one does too :)

Had a cuo of tea and some fig newtons and your show before bed. Perfect evening. God Bless you and yours Dangar Stu.

Great Comradeship, see Adrian helping yoy and you Stu helping Pete. And showing us too. Great for the Successful Outcome too 👍👍🚣

Very interesting Stu, great job on the port heat exchanger which looks and operates so much like new that the starboard heat exchanger got over heated with jealousy. Jeff in LA USA

Hi Stu, Good job on that one. Reminded me years ago helping a friend with his boat with two rebuilt 327 small block engines. I asked him what was wrong he said nothing he didn't know how to set the timing on the new rebuilds. We got there and the boat front was sunk at the marina but didn't get to the motors fortunately. Got the bulge pump working and start getting all that water out while I started on the motors. First thing I found was the distributors were both out 180 degrees. Got them set and hooked up my timing light. Both motors fired right up. He dry docked it the next day to find the bow had a leak and being a wood boat got into it and patched it up. It had twin brass props which was cool. The boat was a cabin cruiser from the 40's

The joy of boat repair ,when 1 is done another shows up. The never ending story.....lol great video, great DYI repair.

Good job. Thank you Stu.

30:20 the thermostat go's UNDER the gasket and sits directly on the block opening and the gasket go's on top of it

Your chickens are very very spoiled. And it was nice of you to help out your mate, as you often do, Stu.

3:54 feed the shank of the tap up through the hole and tap up (instead of down). So long as you've got 1 full thread to align the tap and take it very slowly you're golden.

Nice win for the port motor. I kept wondering when you were going to get out the spray bottle with soapy water in it. That could have saved a few trips to the dock.

I don't give the screwdriver handle too long inside the bottle Stu. Love the work though well done. Only one to go now!

Jumped back and watched again.. Great vid.. Thanks.

Stu, you are very resourceful! I guess that is what makes you able to do your thing. Also, very entertaining. Thank you.

Perfect way to end a snowy day in canada!

I love the time-sert thread inserts you used. so much better than heli-coil repairs.

Thanks for another excellent video !!!

Enjoyed seeing your broody hen. Chickens are funny. We got 16" of snow here- it's just melting - but our hens think it's spring. Normally, we are getting 2-3 eggs in February, but we got 18 eggs yesterday, out of 21 hens. The kicker is that half of them are old and stopped laying years ago. That's crazy. Seeing blue and green and pink and spotted eggs again. The old girls still have a few left when they feel like it! Seems like putting the remote door opener has something to do with it. Egg numbers have gone up consistently since then. Maybe they feel more secure at night? Or maybe the older hens are forced to smell the pheromones of the younger girls, and want to compete, since chickens compete at everything? Who knows, but we have lots of eggs for friends and family.

Great job

Live stream outboard repair... Keen!

Sweet! something to watch on a rainy Sydney afternoon.

"every job you do gives you five more to do" man that's brilliant

Hi Stu , absolutely love your work area where you do all these projects with all your tools and equipment , it is the kind of workshop all Men need in their lives .

He does a great job of videos. It reminds me of the grand Banks I bought in the first two weeks I rebuilt 14 water pumps mention it to the neighbors on the boat next door they said they're not surprised it hadn't been away from the dock and four years except for the sea trial. I asked them why they didn't tell me that when I was looking at it and they said they're friends of the owner and I asked him how come they didn't tell me Well now they're friends with the new owner they can tell me.

We run that same orange rtv in place of header gaskets or exhaust gaskets on cars and trucks so they can handle a lot of heat and it works great and almost never leaks

Great instructional video. Well explained and interesting as always. Good work Stu.

I might suggest retrofitting an exhaust manifold from and industrial or truck engine without a heat exchanger built in and using a plain shell and tube heat exchanger. You can use a header tank with radiator cap built in from a source of hot rod and race car parts. I've done this on several Isuzu and Perkins diesels in the past, with exhaust manifolds wrapped in non-asbestos wrap and it works fine. The manifold temperature stays lower than you'd expect. Make a wet elbow from stainless pipe fittings with a seawater injection pipe welded in. That way you'll have no sketchy aluminum parts exposed to seawater. Lobster fishermen in Maine often use this setup with a keel cooler made from copper tubing and a dry exhaust. Good Luck!

👍thanks hope your well

Nice one Stu on the repair as for daisy yep got the same as but my other chook hilary isn't paying her rent in the coop where green eggs she is old and still producing lols look forward to next vid , cheers ,shaneo, nelson ,nz

I’m learning so much from your site. Thanks Stu!

...busy busy,,lol,, good one, keep safe and have a great week...

Looks like you guys did a fine job!!!

Tip for at 27.45 if you can’t find the hole, try putting a bit of hair round it, that usually helps.

Stu I saw the recessed lip of hole where the thermostat went and thought it might go under the gasket? André

In Egypt the boat crews would run a rope through the mooring bridles then back to the boat that way you have more control also the option to cut it if it is going wrong in a hurry. Good fix on the H Ex

Great stuff guys - well done

Stu, the Vetus part number for the aluminum manifold, heat exchanger housing is: STM7551

Nice one Stu,keep up the good work and take care

Wow, amazing episode! There is some “Adrian” looks in you now :)

I will watch the live stream of the outboard engine diagnosis and fix, Stu. Let us know when that will be aired.

Hey Stu, grab yourself a rifle bore cleaner kit with various caliber brush sizes, cheap tool to mechanically clean tubes like in the heat exchanger, if you can access both ends bore snake are brilliant.

I found the epoxy let go on my old ford heat exchanger after a season. Your prep was better than mine though. I've marinized a pair of Cummins truck engines on my channel. Used mani-headers and separate head exchangers, I think that is a much cheaper option if you have to replace the vetus ones.

The way they clean boilers (heat exchangers) in industry is to run hot moderately concentrated HCl (hydrochloric acid) mixed in water through them. The Cl atom combines readily with corrosion like Magnesium creating a water soluble salt (MgCl), which can then be flushed away with water. It produces Hydrogen gas, which needs to be vented properly during this operation. It doesn't attack metal because it isn't in situ long enough to do that, it is only in the heat exchanger for15-20 minutes.

In this episode our hero Stu takes the role of Jedi Engine Master and Pete is the Padawan... 03:20 09:30 Good see Pete taking workshop safety seriously with the appropriate 'safety thongs' for footwear :) 20:30 but ditches them on his own boat I always find dies and tapping to create threads somehow magical - odd I know.

What I'd give for a few days on the water in that glorious weather. UK so depressing this time of year.

Nice repair Stu!!!!!!! Now you have to do the other one. Keep up the great work!!!

enjoyable video thanks!

This channel is awesome. Thanks

Ps . Loved this video. Can wait for the starboard motor. Now you mate is trained, you should become the TA and let him do the work!

For once my notification did there job, good work there sir.

Nice job with the time-sent. I’ve seen guys who claim to be pros install the insert above the surface and they won’t work and of course it’s not their fault.

Good work Stu. I like it when you think outside the box. Something you can try sometime for bolts that are subject to moisture, dip the threads in Stockholm tar

thanks again.

well done

Thanks again....My friend...Cheers

On a boat, on an island, with a buddy, with some beers and fixing things...

Hey Stu, when you change that gasket on the thermostat, will you check to see if that thermostat goes under the gasket. I thought I saw a recessed cavity in the engine housing. I hope I'm wrong, just hate to see it crack the housing. Also might bring an extra thermostat incase I'm right and it crushed part of the flange of the thermostat. Good job on everything. Seeing you in that hull working makes me glad I don't work on boats! I would've had to cut more of the floor to get in there. Definitely deserves a beer after that!

Good Fix Round 2 Coming Up

Cool vid Stu, cheers! 🍻

Nice. Must admit I was sceptical about the repair. Looks good, though. RTV, brilliant stuff, but has been the death of many engines sealing where it shouldn't. Good to see you using it very sparingly. I guess from the discussion that this has a wet exhaust.

Great stuff Stu You can fix anything Ill call you when I next breakdown :)

I know I have commented before. Have you ever tried Permatex "The Right Stuff"? Used it on water and rear differential on my diesel. Never a leak.

Tan me hide when I’m dead Fred. Tan me hide when I’m dead. Song was stuck in my head the whole video.

Hey Pete, wassup!

Adrian has humbled us

Yippee I'll get a good night's sleep tonight..fun with Stu 😎😎

You can likely purchase aluminum plate and pipe and weld that onto the remaining metal. It will be much cheaper and if it doesn't work you could always fall back on having the piece machined. Just a thought.

20:39 Stu, stainless is not as "brittle" as mild steel (it's actually quite tough). A470 grade SS bolts (probably the most common in Oz) have an ultimate strength of 700 MPa (not far below a Grade 8..8 of 800 MPa) but a much lower yield strength of 410 MPa (compared to 640 for a Grade 8.8), so SS bolts will "stretch" (elongate) for a if they are over-tightened without increasing their effective clamping force until they snap. (Clarified for the record)

Boxing Day 2020 seems like a lifetime away now 😩

Hi I’m Shane love yr show been watch it for some years. Just asking have you every worked on a Volvo MD1 marine diesel….

I love your videos!

Those ovehead reels are not quite Zane Grey era but they sure have some vintage old school cool Stu

Hey Stu, did you have any more vids of your trip south? And i hope your mate in this one stocks Renko with some good whisky, or something for all your hard work.

Nice repair. The only issue with cutting the end of the other one is it’s cast aluminum. Welding cast aluminum is rarely successful. I’d consult a welder before you have take the plunge. I’ve never had any success welding cast aluminum’s. I can weld cast iron all day long. It’ll have to be TIG but even that is difficult. Cheers Jeremy K.

Keep them coming! Love the content!

Stu starting to sound like Adrian now! 😀

Sweet we have snow on the ground and Stu pops up... Stu I have done weld repairs to cast aluminum manifolds... to be very honest there is no easy way to repair them. What you have done is about as good as anything that can be done. Your comment on cutting the end off and welding a plate on is a poor idea because you will have two or three different aluminum alloys in close proximity with copper/bronze alloys is the making for corrosion issues that will be bigger than what you had over time. What would be a better idea would be to put the manifold in brown vinegar let it eat away the corrosion then weld up the corroded areas and machine those surfaces. I'll let you know your tig welder doesn't have the amperage needed to do proper welds on that manifold. It will take 300 to 350 amp tig welder to get the heat into that manifold for good welds. You will be floating corrosion and contamination out of the casting as you are welding so keep a die grinder with a course burr handy. Did anyone check to see if the right anodes were put in the heat exchanger? Aluminum uses a different anode alloy then used on steel or cast-iron components.

Not sure whether the screwdriver will last longer in the metho than in the boat - please let us know

Hey Stu, what ever happened to the second heat exchanger on Whitecrest? Did you end up fabricating the 'new' part?

Isnt it normally thermostat then gasket followed by housing? Looked like there was a lip for the thermostat to sit in... other wise love the vids. Wish I could find one of them as a project here in the states.

I might've missed something, but I think the overheating engine was the one not running a thermostat? Depending on the engine and cooling system design, some engines WILL overheat without a thermostat. The coolant is moving way too fast for proper heat transfer.

What kind of grease are you applying to the gaskets?

Quick tip : when installing the exchanger or exhaust manifold, if you have room use studs to slide the piece on and hold the weight also they will line everything up.

nice

Could that be a MHI S4S? I see them every day but I never get to work on them as there is never anything wrong with them :)

What no never seise on those exhaust bolts?

Generally there is a long generally brass/ copper alloy stud that runs right through the heat exchanger to hold the end caps on, generally of course, highly dependent on make/model, personally never seen an actual thread into a heat exchanger?? Maybe I have been enlightened by this video 😜

thanks for the video ! i suspect that going the aluminum replacement machining will cost more than a replacement unit...its part of our design for throw away consumption society problem where most things are no longer serviceable,,,

What kinda juice did you put that screwdriver in for "water repair kit"? I think you said methyl, but your accent got me.

If you cut the end off the heat exchanger be sure that the alum is not corroded as if you try to weld it it will explode as the salt and the alum when heated turns to hydrogen as I have had this happen to me twice and what a mess of the alum it makes.