OP
OP
Thanks.
Krogen 42 Fuel Tank Replacement
- Thread starter Larry M
- Start date
The friendliest place on the web for anyone who enjoys boating.
If you have answers, please help by responding to the unanswered posts.
If you have answers, please help by responding to the unanswered posts.
Thanks.
OP
OP
Thanks Scott. We did lose 5 days with Hurricane Matthew, six days on the port tank and Greg's heart issues did slow us down a bit but we had great weather for us anyway.
OP
OP
...3 days is enough for the new mounts to settle, alignment after splash? Any time for her to regain her "in the water" shape?
Very nicely done,
Thanks.
St John's Boat Company doesn't have a place for Hobo to get her shape back when we splash unfortunately. Todays plan is to see how the alignment is, get it as close as possible and then take Hobo to OLM, about 20 miles up the river. Then we can sit for a week or so before we do the final. It's not ideal but .....
OP
OP
Thanks. Cardude: Post your projects. The little ones count to. Those are the ones that can eat you down the road later.
OP
OP
+1!!!
Thanks for the kind words and support. There were a couple of times, well maybe more, when I was wondering, WTF I was doing and you guys plus many others, helped keep us going.
OP
OP
Thanks. I may be getting a hold of you when we get ready to install the PEX. I've never worked with the stuff but it seems like the way to go. You've confirmed what we've been hearing.
RT Firefly
Enigma
psneeld
Guru
I will be down in early Jan, you can borrow my crimp toolunless planning to get started earlier.
RickB convinced me to go to the stainless crimp route for connections not likely needing to be changed frequently.
They are way cheaper than the push on connections, and when I redid MY WHOLE BOAT, fresh, salt and now I wish I did the Air conditioners both supply and drains too, it would have added up.
Not one ever leaked after crimping, even the one handed crimps way back behind things....it has been 2 years living aboard since the job.
There are a few connections that I may rethink and go push on as time goes along....just for convenience.
I bought bulk from a place called supplyhouse.com. very inexpensive and I went with the slightly more expensive but more flexible pex. Great service and pricing.
http://www.supplyhouse.com/
I did not use a manifold, just in line valves to shut down pumps, or boat sectors for maintenance. The manifold idea is nice if you have a lot of sectors or individual items....but it may mean much bigger access holes through bulkheads, etc.
mbevins
Guru
Larry... Besides the obvious great looking ER now I was amazed that when I went back to the start of this thread to see when you started is was just 2months ago. Then if you back out Matthew and stuff you did this whole project in basically 6 weeks. That is pretty amazing. I'm glad it worked out for you.
Almost time to put her back to work!
Almost time to put her back to work!
Moonstruck
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A big well done! It has been an amazing project. Thanks for letting us tag along.
OP
OP
A big well done! It has been an amazing project. Thanks for letting us tag along.
You guys kept the pressure up. Particularly Don when he set the dates for the TF gathering in Fort Pierce. Maybe we can have a TF demonstration on installing PEX. :lol:
OP
OP
OP
OP
Living on dirt was a big motivator to get the job done. We're not ready to swallow the anchor. Tonight we'll be sleeping back on Hobo.
OP
OP
Plans? We have no plans.
If all goes well, we'll be leaving JAX in January for the 2nd annual TF gathering in Fort Pierce. After that probably, the Bahamas till June. But first we have to go in the water. We splash this afternoon. 
Mainship400
Veteran Member
Larry and Lena. So proud of you two!! Awesome job of documenting a challenging project. A real benefit to the community!!!! I can't wait to see you.
OP
OP
Great project Larry, smooth steady pace even with a hurricane in the middle . Careful planning was obvious .Hobo is feeling the love . Hats off to you two .
Thanks Marty!
OP
OP
Thanks John. We'll catch up with you in the end of February early March for sure.
North Baltic sea
Guru
You've done a great track, great restoration project itself. Trace your way around you can be proud of and pleased with it.
Great that you shared it with the images and text in the Forum, thank you for that.
Great that you shared it with the images and text in the Forum, thank you for that.
OP
OP
Hobo's back in the water with the tanks holding fuel and the engine running. Yahoo!
Here are the numbers:
Tank Construction: Includes tax, no transportation $10,529
Engine/Running Gear Rebuild: no transportation costs $12,558
Boat Yard: haul/block/launch, fork lift, crane, some tools and minor parts $4,562
Subcontract Labor: 86 hours $6,240
Stuff: Perf al panels, plywood, parts, more tools, hose, etc $3,800
Ouch $37,689
We were under budget on the subcontract labor but that doesn't take into account the 400 plus hours that Lena and I put in. It's difficult to say what costs were specifically for the tank replacement. The engine rebuild is easy to separate out, but not everything is as cut and dry. We had to replace the existing ceiling and wall panels. There was too much damage trying to remove and then reuse them. How do you do this job and not rebuild/replace the thru-hulls, hoses and some wiring? Another area that took additional resources was the re-configuring of the engine room. With each tank 22” shorter, we removed or modified nine mounting platforms. We could have used the existing ones and saved at least a week but how would it have looked?
Would we do the same thing again? Probably. We didn't feel we had many alternatives. A band-aid approach could have sufficed, but would have been hard to live/cruise with. We also considered the option of handing the project over to someone. We talked to one local yard (Lambs) before hand. They have the ability and resources but at $90/hour and no owner involvement, we estimated the project would have been north of $70,000.
I'd like to thank everyone for the support and coming along for the ride. To think that I initially hesitated to post this project before it was done (think armchair quarterbacks, backseat drivers-you know the potential). What a mistake that would have been. At the end of the day, you guys helped keep us going. Thanks!
Here are the numbers:
Tank Construction: Includes tax, no transportation $10,529
Engine/Running Gear Rebuild: no transportation costs $12,558
Boat Yard: haul/block/launch, fork lift, crane, some tools and minor parts $4,562
Subcontract Labor: 86 hours $6,240
Stuff: Perf al panels, plywood, parts, more tools, hose, etc $3,800
Ouch $37,689
We were under budget on the subcontract labor but that doesn't take into account the 400 plus hours that Lena and I put in. It's difficult to say what costs were specifically for the tank replacement. The engine rebuild is easy to separate out, but not everything is as cut and dry. We had to replace the existing ceiling and wall panels. There was too much damage trying to remove and then reuse them. How do you do this job and not rebuild/replace the thru-hulls, hoses and some wiring? Another area that took additional resources was the re-configuring of the engine room. With each tank 22” shorter, we removed or modified nine mounting platforms. We could have used the existing ones and saved at least a week but how would it have looked?
Would we do the same thing again? Probably. We didn't feel we had many alternatives. A band-aid approach could have sufficed, but would have been hard to live/cruise with. We also considered the option of handing the project over to someone. We talked to one local yard (Lambs) before hand. They have the ability and resources but at $90/hour and no owner involvement, we estimated the project would have been north of $70,000.
I'd like to thank everyone for the support and coming along for the ride. To think that I initially hesitated to post this project before it was done (think armchair quarterbacks, backseat drivers-you know the potential). What a mistake that would have been. At the end of the day, you guys helped keep us going. Thanks!
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JDCAVE
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Hi Larry. Everything looks wonderful! It gives me an appreciation for all the work the PO did with our vessel. I just hope that his efforts were as thorough as yours. And of course with everything out it was wise to do a thorough revision of the engine room space. Your won't regret it!
Which panels did you replace? How did you redo the ceiling panels?
Jim
Which panels did you replace? How did you redo the ceiling panels?
Jim
OP
OP
The white painted peg board on the ceiling and the 12"x12" squares on the tank's in-board side/backs were replaced with aluminum coated panels (8-4'x8' sheets) we bought from Soundown. Doing the ceiling was a pia. The ceiling wasn't level and trying to handle pieces that were up to 8' long was difficult at best. The manufacturer recommends that for best results, we should have had at least 1/10 of an inch between the panels and the ceiling insulation. :lol: The panels in fact hold the insulation in place in some areas. So far we haven't noticed any difference/increase in the dB level. We weren't looking for any improvement in sound reduction just something to replace the 29 year old peg board.
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Larry and Lena, Great job! Very impressive timeline and cost for all you accomplished. What happened to the old engine? Trade-in?
Looking back now, are there areas you wish you had more time or money to complete that got bypassed on this job? From this seat, it doesn't look like you skipped much.
Thanks for showing us how it's supposed to be done!! You've really raised the bar for the rest of us.
Looking back now, are there areas you wish you had more time or money to complete that got bypassed on this job? From this seat, it doesn't look like you skipped much.
Thanks for showing us how it's supposed to be done!! You've really raised the bar for the rest of us.
JDCAVE
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Oh right. I thought you were referring to the Saloon. The PO used that reinforced aluminum foil/sound barrier material in the ER, surrounding the tanks and the ceiling. Probably not as durable as the material you used.
OP
OP
Thanks Al! This is the old engine. The engine was completely torn down and the block cleaned in a hot dip tank (sodium hydroxide). The oil pan was bead blasted. The block and head were magnafluxed.
Here's a list of most of what was done to the engine:
Exhaust Manifold cleaned and pressure tested,
Bore the Block
Grind and Polish Crank
Reconditioned Connecting Rods
R&R Wrist Pin Bushings
New Pistons/Rings/Pins
New Main Bearings
New Rod Bearings
New Cam Bearings
New Cam Thrust Washers
New Front and Rear Seals
Remanufactured Raw Water Pump with Gaskets
New Fuel Lift Pump with gasket
New Circulating Fresh Water Pump with Gasket
New Thermostat and Gasket
New Valves
Grind Seats
New Injector Tips
Remanufactured Injection Pump
New Engine Oil Cooler
New Water Hoses (all)
New Heat Exchanger
New Oil Lines
New Starter
We did have an issue with the cam. One of the lobes was out of spec and was shipped to a specialist in the mid west. They built it up and reground it.
The running gear had new bearings, clutches and seals. I'm waiting for a complete list for both.
Looking back I do wish I had more money and time.
But at the end of the day we just wanted to get the project done. We live on Hobo and were renting a cottage. The rent plus the daily yard costs took a big bite. I guess our only complaint is that the boat yard was so remote. The closet hardware store was 20 minutes and the closest marine chandler was 25. For some things, I would order them by 2:30 in the aftenoon and have them over-nighted to the yard. It was cheaper to pay the shipping costs then go to West Marine. A RT parts run was 1-2 hours. Lena knows more about boats and parts now then most clerks.
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Keysdisease
Guru
I know part of Larry and Lena's success with this project, and especially the timeframe, was planning and more planning. Getting vendors, parts, components, labor and everything else that goes into a project like this lined up well in advance keeps the surprises to a minimum so you can deal with the real unexpected surprises without it taking too big a bite out of schedule or wallet.
You can't plan ahead too much or get things rolling too soon for a project like this, the price per day is too big a penalty.
Again, nicely done
You can't plan ahead too much or get things rolling too soon for a project like this, the price per day is too big a penalty.
Again, nicely done
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