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Day 193, Engine, finishing heat exchanger installation.

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Engine Installed heat exchanger. Decided to mount it above the wet muffler keep it as close to engine as i can and mount it leveled and keep it high enough to make air naturally run out of engine. To install it there I made a  mount and screw it to the engine compartment wall. 2 hours to put it tight, but stand off of exhaust.I have about 2 inches clearance from wet exhaust hose. Little straggle to find place for coolant expansion tank. For now I put it to the wall little bit right from picture view area. Connected transmission control and engine stop cable. adjusted idle RPM and accelerator cable to do not interfere with idle speed screw.  Temporary installed engine monitoring controller.  Controller designed to collect engine data and transfer to SignalK server. Then I will be able to indicate all on the cockpit display. For now it is very important to monitor engine temperature to confirm the engine is working without overheating and thermostat works correctly. I plan ...
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Day 192, Engine coming back to the boat.

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 Engine Preparing engine to travel. Engine secured  to dolly. 3/4 plywood "skid board" mounted at dolly foot. 7:30AM came to marina. Assembled the crane, hoisted engine and moved car out. Good buy my crane, crane was made from 2x4  and 4x4 posts. Worked well for me all time I worked on engine. I decided to "donate" it  to the marina community. Engine waits to descended. Descend in progress.  Two cars used.  Rope tied to engine, goes to pulley on the to of the hill. (block mounted on the car hatch),. then rope goes to second car. Second car controls rope tension.  To slide on stairs we used 4 boards. 2 at time. Came to the boat, chain hoist set on boom to load an engine. In a process of hoisting Engine is on the boat! Lowering it in the engine compartment. A lot of effort to put it on the place, but we have done it ! Engine is at home ;-)  
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Day 191, Engine Fresh water conversion (continue) , HVAC air dirtribution finalising. Check checkvalve colution to keep water in AC pump, installing engine mount metal angles.

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 Engine  Still working on fresh cooling conversion. A lot of learn, check, try, source, return (thanks Amazon), weld, paint, try again.   LINK TO FULL REPORT IS HERE   Engine assembled and run with  dual cycle cooling system.   During test run digital temperature sensor showed 68C maximum on free run engine for an hour. Technically, without load i can't get engine to produce enough heat to run thermostat fully open. Partial opening makes to cool enough. More testing will be done on the boat. Hope for better;-)   Also I found one overheat sensor 95C tripped alarm during the engine test run. Other did not tripped at all. Tested first one in the bucket with water on the stow,  it is tripping about 65C, however it marked for 95C. Second one did not tripped in oil bath up to 150C - likely it is not an ALARM switch.    [update] Custom water manifold replaced with T connector, it gave me an inch to lower thermostat ant top hose. Engine mount p...
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Day 190, HVAC air dirtribution redo, adding checkvalve to AC water discharge to prevent pump from drying. Engine, cooling system modelling, Dry bilge collector.

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Weekend off.  I lost previous weekend because stuck in business trip. No post sometimes means nothing done,  Air conditioner  Since I took engine home I had a problem.  HVAC water pump was not able to start due to waterline appeared below pump level resulting water run out of pump. As soon as pump ins not self priming it did not work. To fight the situation I added  check valve near AC water discharge preventing water run back and let air to pump.   Originally, I built some king of silencer here, but it took a lot of volume and really did not silenced ait flow too much.  So, silencer removed and replaced with Y duct now.  Second thing why I gigged here was the  problem with electrically controlled valves. I thought one of them just broken, but it appeared the issue in connecting them in parallel. DO not connect these valves in parallel, otherwise they back feed each other and never stop. Decoupling diodes must be installed on the ground lines...
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Day 189, Engine mount angles painted, work on fresh water cooning, engine compartment fit.

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Engine  Fitting fresh water pump to engine. Cut and built new flat front lid to engine head from 12mm steel. Built another plate to accommodate water pump to the place. Before cut/drill/tap  plate I prototyped it with plywood head lid and lexan pump plate.    Belt positioning check and required belt length prototyping. Copper wire used as extender. Parts final  cut.   <<Image>>   Check with real belt <<image>>   Parts painted  and waiting installation     Manual starter  Drilled handle side sprocket shaft for the pin. Actually appeared not easy task - Shaft is made from HSS does not easy task. I had heat it up to red and slowly cooled down, then I was able to drill it.   Another piece - handle. Idea to make adapter to winch handle to use it as starter handle as well. I took piece of thick wall pipe 29x19 (5mm wall) drill it to 20 inside, then add slot for the pin on the sprocket shaft on one side an...
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Day 188, Engine mount angles dry fit and adjustments before paining. Galley countertop re-oiling.Cushions calculations.

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 Engine    Mounting angles drilled and taped. Dry fit them on place to make sure they fit and engine mounts will be positioned properly. Pre-drill  holes in the wood blocks for lag bolts.  Planning to prime and paint steel to protect it from elements.    Interior Re-oiled galley countertop. Calculated cost of materials for interior cushions.  Proximate dimensions of all pillows to calculate how much materials I need.  Total facing canvas required - 20 yards and 10 yards backing. 7 zippers - about  40 ft total length + 204ft, (68 yards) of piping (not in the list)    
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In meantime at home garage... Engine updates.

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 Engine. Working on two projects  1) Switch to fresh water cooling.   Engine is in a very good shape. Likely it never saw salt water. I would like it work for me virtually forever. I want to nave hot water on the board and better to have option to use  cooling water for boiler. Yes, system coming more complex, but i hope benefits are over concerns. For now I am in prototyping stage.  Likely will use water pump from pump. (19327-42100 Water Pump For Komatsu Engine 4TNV84 ). It looks descent, much easier to source than original 2QM20 fresh water pump. Belt pulley from tractor Yanmar YM146 tractor. Pulley has small diameter and fits pump, deep pulley gives more space behind the pump. so i will be able to maneuver there. \ Heat exchanger likely will be  https://www.mrcool.us/2qm20-yanmar-heat-exchanger.html  Likely, I will take "in line" thermostat. Will put some updates later. 2) Add manual starting option "back" to the engine. Looks like my particul...
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