dirtniron
Newbie
I have been required to replace the engine exhaust hose due to noted surface "cracks". The hose is original to this 1987 made vessel.
The hose is heavily corrugated, 3 1/2" ID and quite stiff. Noted is that it is unmarked other than a stamping found at the stern end. This area is obviously enlarged due to extra material at that end to fit over the fiberglass exhaust flange extension. Being factory original I noted a white silicone was used as a sealant along with the clamps. The hose runs along the port side and is supported in the aft locker with an inverted "J" hook, thence fwd thru the bulkhead neatly sealed with wood shroud, thence outboard of the port fuel tank with another inverted "J" hook. This was the challenge - not to lose the hose passing over this unreachable hook. Thence passing forward of the fuel tank and aft of the holding tank, supported there in an inverted "P" strap that disconnects easily, then turning inboard over the sensitive refrigeration components and a maze of drain hoses to the exhaust muffler.
With the sharp bend of the hose near the engine I elected on pulling the hose fwd into the cabin, feeding the new in from the stern locker.
Rather than damaging or removing the refrigeration unit, I built a simple 3-sided wood box with cover to use as a working bench (1 by 8 inch rough cut white pine I had and will plane down later to make an onboard storage box)
Pic 1104 shows step one removing by prying off the 2-piece bulkhead shroud. Place a long thin metal or wood strip under this hose to allow easy riding of the corrugated hose along the bulkhead.
Pic 1107 shows the saw-Z-all cutting the hose to allow rotation and sliding off from the exhaust fitting. May require careful surface slicing of hose to cut internal wiring and allow movement.
Pic1120 looking outboard, next to engine, shows the wood box in position. The muffler had to be removed to do this, but the extra room was required anyway.
Pic 1128 and 1130 shows the PVC plastic insert I used to attach the new hose to the old to allow following during removal. Two screws on each end held it all together.
Initially with two persons the push-wiggle-pull technique worked for about two feet then no more. Extra muscle may have worked but was unavailable. Using the wood box as a pry-table did not help dislodge the hose. The heavy corrugation was a problem. Time to stop and rearm. I went out and bought a smaller-than-I-have come-along (cable winch). With more blocks and wood pry bars I returned.
Pic 1132 shows the winch attached to the fwd engine lift ring, carefully routed over a padded engine. Pic 1133 shows the rope bridle fastened to the hose, thru the maze of hoses. Due to space limits only about 10 inches of travel was possible at a time. The cable would take up a good load then the hose would slip about two inches at a time. The friction spot was at the front outboard side of the fuel tank vertical support framing, not reachable by hand and the hose too stiff to move outboard.
With the new smooth #250 hose in position, it slides easily and should be no problem to reconnect and cut to length in the near future.
The hose is heavily corrugated, 3 1/2" ID and quite stiff. Noted is that it is unmarked other than a stamping found at the stern end. This area is obviously enlarged due to extra material at that end to fit over the fiberglass exhaust flange extension. Being factory original I noted a white silicone was used as a sealant along with the clamps. The hose runs along the port side and is supported in the aft locker with an inverted "J" hook, thence fwd thru the bulkhead neatly sealed with wood shroud, thence outboard of the port fuel tank with another inverted "J" hook. This was the challenge - not to lose the hose passing over this unreachable hook. Thence passing forward of the fuel tank and aft of the holding tank, supported there in an inverted "P" strap that disconnects easily, then turning inboard over the sensitive refrigeration components and a maze of drain hoses to the exhaust muffler.
With the sharp bend of the hose near the engine I elected on pulling the hose fwd into the cabin, feeding the new in from the stern locker.
Rather than damaging or removing the refrigeration unit, I built a simple 3-sided wood box with cover to use as a working bench (1 by 8 inch rough cut white pine I had and will plane down later to make an onboard storage box)
Pic 1104 shows step one removing by prying off the 2-piece bulkhead shroud. Place a long thin metal or wood strip under this hose to allow easy riding of the corrugated hose along the bulkhead.
Pic 1107 shows the saw-Z-all cutting the hose to allow rotation and sliding off from the exhaust fitting. May require careful surface slicing of hose to cut internal wiring and allow movement.
Pic1120 looking outboard, next to engine, shows the wood box in position. The muffler had to be removed to do this, but the extra room was required anyway.
Pic 1128 and 1130 shows the PVC plastic insert I used to attach the new hose to the old to allow following during removal. Two screws on each end held it all together.
Initially with two persons the push-wiggle-pull technique worked for about two feet then no more. Extra muscle may have worked but was unavailable. Using the wood box as a pry-table did not help dislodge the hose. The heavy corrugation was a problem. Time to stop and rearm. I went out and bought a smaller-than-I-have come-along (cable winch). With more blocks and wood pry bars I returned.
Pic 1132 shows the winch attached to the fwd engine lift ring, carefully routed over a padded engine. Pic 1133 shows the rope bridle fastened to the hose, thru the maze of hoses. Due to space limits only about 10 inches of travel was possible at a time. The cable would take up a good load then the hose would slip about two inches at a time. The friction spot was at the front outboard side of the fuel tank vertical support framing, not reachable by hand and the hose too stiff to move outboard.
With the new smooth #250 hose in position, it slides easily and should be no problem to reconnect and cut to length in the near future.