My A4 adventures

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  • Ando
    Senior Member
    • Jul 2019
    • 246

    My A4 adventures

    Hi everyone, so here it goes:

    The back story:
    I've been bitten by the bug many years ago and have been searching for a sailboat, off and on, for the past 10 years. I saw ones I've liked throughout the years but I didn't jump on them until I found the "Tiare" in October 2018. (A Tiare btw is a type of Gardenia Flower found in Tahiti)

    Note: Just because I searched for a long time doesn't mean I knew anything about boats, let alone motors. In fact, I had absolutely no knowledge about either other than making sure it floats and maybe changing spark plugs.

    The Honeymoon:
    I took her out maybe 10-12 times from Oct 2018-Aug 2019 and we started getting acquainted. A mini adventure was finding a dinghy for her (maybe another thread, but I had a steep learning curve on that adventure as well).
    She taught me a lot during that time (she is a year older than me after all), but I began noticing little issues (rain water seeping through her port side aft eye, minor minor deck wear here and there etc.) but what bothered me the most was the stalling of her A4 heart, which to a tremendous lack of piece-of-mind. I want to feel comfortable sailing with my two children, family and friends who will be looking to me if anything happens on the water.

    The Afourians:
    I googled "A4 expert in San Pedro" and that's when i found you all. The post I read was from a guy who coincidentally had the same problem as mine...stalling. He said he searched the forum and is pretty sure the problem is coming from the carburator, but that he was not confident removing let alone rebuilding a carburator. Sounded a lot like me, except that I didn't even know what a carburator looked like.
    He asked if someone would recommend a mechanic and two offered to go out to take a look. Those two were Thatch and Ndutton. I looked them both up and saw a weird moniker next to their names, which read "Afourian MVP". I immediately reached out to both of them and Ndutton came out to see me.
    A few hours of talking with Ndutton was worth many many many hours of researching and re-searching for answers. He talked and I listened and took notes. When we were done, I felt confident I could remove the carb, rebuild it and what parts to order and what I should do next (which was to refresh the whole fuel system). I refreshed the fuel system only with the advice and thx to ndutton whose patience in dealing with my newbie questions is still remembered and cherished and dare I say it, continuing
    The motor worked so well in fact that I ran it and ran it hard. I was so impressed that I forgot the fact that engines need oil... and it soon developed a knocking and once ndutton came by and heard it for himself I found out that the knocking was one that would require it being pulled out of the boat. No, I didn't cry fyi. I was happy to know exactly what I had to do thx again to ndutton. Oh ya..and he told me that the motor was an early model A4, where it should've had a late model A4 so I assume the Tiare wasnt telling me everything and that she had been around this block before.

    Rebuild or buy?:
    $3500 rebuilt vs. ~$2000 to rebuild is what I found. Until I found a late model on FB for $900! Made sure it worked, borrowed a truck, scooped it up and brought it back along with a million other parts and toys that the seller unloaded on me for just another $100 (such as a whisker pole and sails for it, magna stabilizers, half of the EWDS, full set of brand new gaskets, adjustible alternator arm, etc, etc etc) realizing (too late) that I have no way to take her out the bed of the truck once I get back into town, and I had to return the truck to the owner. Guess who saved my ass. You guessed it...ndutton, that's who. He brought over two planks to make a ramp and we wheeled her off (yes, she was on wheels thk goodness).
    So, my question was answered for me...the answer is Both.

    The swap:
    So as the story goes, I had one working late model on the slip that I was buying new and improved additions for (EWDS, therm + housing, water pump, water jacket stud kit, etc etc..I guess Don can chime in and say what else I got and one handicapped early model on the water slowly being dismantled.
    A few days before the swap (I had a boom mounted winch) the Marina told me that I'd have to do the swap at a boat yard...mind you I could've motored it to a yard before I had taken it all apart...now I'd either have to put it all back together to motor it or just tow it. Thankfully I had US Boat Towing and they towed it for free. Might as well get the bottom painted $$$ (I got sick of seeing the monthly report from the bottom cleaners saying the bottom paint was "poor"). Might as well have it buffed $$$.
    Got it back a week later (end of Oct. 2019...about a year after purchasing it) and had to tow it back bc the new motor wasnt nearly ready to run (prop shaft not even connected). Took the old motor to the house and began tearing into the block while slowly reconnecting the new motor.
    All the random research I did in the past was now making sense and paying off with info on such things as feeler guages, motor mount adjustments, EWDS bell and whistle placement etc.

    To conclude (though it may never end):
    New motor - I just put the wiring on the new motor so she has power and I put MMO under each (brand new) spark plug. Just ordered a brand new the instrument panel (bc I really dont want to put the EWDS display anywhere else) and the OPSS. When I get those, I will install them and maybe, maybe fire her up before that just bc I'm curious...but not until I add oil :)
    Old motor - I found that the knocking was coming from the trashed journal connected to the piston in cylinder #2. Got a quote to hone and machine the crank shaft (~$200), but not to straighten it (which I wont know if it needs it until I take it in). Now I need to contemplate if I will rebuild or sell off the good parts. What you guys think?

    Final Note: every little thing I did was a pita...nothing, and I mean nothing was easy. Removing bolts for example was a mini adventure...I had to buy a specific wrench to remove a stripped thread. But nothing worth while is easy and it is a really nice hobby to have IMO and I love it and consider it fun. So there you go. I'm sure I'm with like minds. "Hi everyone, my name is Ando and I'm an Afourian"
  • GregH
    Afourian MVP
    • Jun 2015
    • 564

    #2
    Welcome Ando!

    Keep plugging away, one step, then the next and soon it'll be all there!

    You are in great hands out there with the fount of wisdom locally and backed up on here.
    Greg
    1975 Alberg 30
    sigpic

    Comment

    • Dave Neptune
      Afourian MVP, Professor Emeritus
      • Jan 2007
      • 5044

      #3
      Great Start

      Ando, well stated. Bill, this could be an intro "article" for the MMI site. Anything can get done with determination and good helpful information.

      Welcome aboard. You were in good hands with Neil & Tom who are among the some of the Afourians I have shared stories and a beer or two. I still hang around the site as I am an old engine nut now without an old engine. I still have a sailboat but it is diesel powered and I still get good maintenance info regarding the boat stuff here first if possible.

      Fair winds _/) _/)
      Dave Neptune

      Comment

      • wristwister
        Senior Member
        • Nov 2013
        • 166

        #4
        Great story Ando, and similar to many of us who've had to "learn by doing" on these A4's. My story is similar to yours, except my knocking turned into an errant connecting rod blasting a hole through the block.

        I think you'll find the biggest benefit to your effort is you now know your motor intimately, and no matter what happens to it you'll be able to fearlessly and knowledgeably dig in and make it all better. That should go a long way toward confidently taking your family out on the boat.
        "A ship in the harbor is safe ... but that's not what ships are built for.

        Comment

        • Sam
          Afourian MVP
          • Apr 2010
          • 323

          #5
          I'll chime in on the early model A4. The last year they were used is about 1969 and then a few 'hybrids" appeared. I have a virgin great running one in my 1966 Morgan 34 which I have had for 44 yrs. [I change oil often and thank the forum]. My point is that they were installed in what are now pretty old boats with old owners if they still around [our wooden boat fleet is gone]. We have about 700 boats [majority sail] in my Chicago harbor [I am the informal A4 go to guy] and I have not run across another early A4 - many late models still running good. I also have a rebuilt late model A4 in storage that I bought 25 yrs ago thinking I might need it one day - don't yet.

          My comment is I don't think there will be any substantial demand for good running early model A4. I 'd limit my efforts and $$'s. However it only takes one buyer who would want a direct replacement?

          Comment

          • Al Schober
            Afourian MVP
            • Jul 2009
            • 2007

            #6
            I've driven down a lot of roads in this life. Some were paved highways with lots of signs, etc - others were dirt, single lane, showed up as dotted on a Topo map, and suitable only (maybe?) for 4 wheel drive with plenty of ground clearance. You tear the muffler off, it's going to be a noisy trip the rest of the way.
            Which roads do you think I've enjoyed the most? Which do you think I'll remember the longest?
            These roads were taken in full awareness that AAA charges a LOT more for a recovery than a tow!
            A lot of 4WD vehicles have an electric (hydraulic?) winch. Usage is about 50/50 for saving someone else and saving yourself!
            What does this have to do with older sailboats & A4 engines? Not sure - seemed germane when I started...

            Comment

            • Ando
              Senior Member
              • Jul 2019
              • 246

              #7
              Thanks for all your comments so far. Really appreciated.

              Since the instrument panel is coming, I'm starting to get ahead of myself and think about my next project(s) to re-wire/clean-up this bundled mess. Getting ahead of myself again because the motor isn't officially running yet. I will keep y'all posted.

              In the meantime, maybe I'll set up a poll as to what to do with this early A4 or a poll to see if I should do a poll ha!

              Thanks again and a special thanks to Mr. Ndutton

              Comment

              • Ando
                Senior Member
                • Jul 2019
                • 246

                #8
                Originally posted by Al Schober View Post
                I've driven down a lot of roads in this life. Some were paved highways with lots of signs, etc - others were dirt, single lane, showed up as dotted on a Topo map, and suitable only (maybe?) for 4 wheel drive with plenty of ground clearance. You tear the muffler off, it's going to be a noisy trip the rest of the way.
                Which roads do you think I've enjoyed the most? Which do you think I'll remember the longest?
                These roads were taken in full awareness that AAA charges a LOT more for a recovery than a tow!
                A lot of 4WD vehicles have an electric (hydraulic?) winch. Usage is about 50/50 for saving someone else and saving yourself!
                What does this have to do with older sailboats & A4 engines? Not sure - seemed germane when I started...
                haha...I'm actually looking into a 1970 Ford Bronco 4x4 (bc I need another project I guess), so your post is actually perfect. I'd say serendipitous. Regardless, it is appreciated and noted. Thankfully, the Bronco has a winch. Not sure if it works, but now you can be sure that I'll test it before my first test drive.

                Comment

                • ndutton
                  Afourian MVP
                  • May 2009
                  • 9601

                  #9
                  I'm glad you found my observations helpful but it should be noted that most members of this forum would do the same thing. Someday in the future you will too.

                  seemed germane when I started...
                  Channeling Sheriff Buford T. Justice from Smokey and the Bandit:
                  The God %@#&ed Germans got nothing to do with it.
                  Neil
                  1977 Catalina 30
                  San Pedro, California
                  prior boats 1987 Westsail 32, 1970 Catalina 22
                  Had my hands in a few others

                  Comment

                  • Ando
                    Senior Member
                    • Jul 2019
                    • 246

                    #10
                    [QUOTE=ndutton;119613]Someday in the future you will too.[/I][/QUOTE

                    I sincerely look forward to that day

                    Comment

                    • Ando
                      Senior Member
                      • Jul 2019
                      • 246

                      #11
                      UPDATE: I got the nerve to put the key in and turn it...wa wa waaa. She didn't start. New fuel lines, new gas/water separator, rebuilt carburator, new water pump, water jacket stud kit, new thermostat and thermostat housing, OPSS, EWDS, new spark plugs and many many many hours and dollars and nothing

                      Ndutton came by and we ran a bunch of tests...
                      Compression: #1 was at 115, #2 at 95 (sparking stopped), #3 100, #4 100
                      Spark: Only #1 was blue/white and the others were yellow
                      Timing ok
                      E-fuel pump test (external tank to inlet, outlet to jug: ok, fuel pump is pumping fuel
                      Fuel tank/carburator test (line from external fuel tank to e-fuel pump inlet): tbd...I havent done it yet. I'll let y'all know. If the engine fires up, I'll know that the issue is coming from somewhere between the internal fuel tank and the e-fuel pump.

                      Comment

                      • ndutton
                        Afourian MVP
                        • May 2009
                        • 9601

                        #12
                        I can add a little more information. On Sunday we performed a few basic tests:
                        1. Ando had already done a spark test. There was spark at the plugs but not of the highest quality. See item 6 below.
                        2. As Ando mentioned, compression test
                        3. We disconnected the fuel hose at the carburetor, put it in a container, jumpered the OPSS and turned on the ignition. The electric fuel pump clicked away as it should but zero fuel flow.
                        4. We removed the polishing filter to be sure it was neither clogged nor installed backwards. All good except no fuel in the filter.
                        5. We did a full timing exercise from scratch (the balloon compression stroke indicator is so cool). Timing and firing order are confirmed correct.
                        6. The coil is in poor physical condition (cracks and leaking around the top). Ando has a replacement MMI coil that he will install. We measured the primary resistance, 3Ω.
                        7. We set the idle mixture adjustment 1½ turns off the seat so it is ready for initial starting.
                        8. By the sound of the starter slowing down, the battery is anemic.

                        Our conclusions/project assignments at this time: replace the coil, test the fuel pump operation (done), find out why there is no fuel pumping from the on board tank and get better battery power either with charging or replacement.

                        edit for accuracy: the tester I used to measure the coil resistance was a very low end V-Ω-A digital meter that rides along in my A4 kit I use for helping others. It reads only integers so although the coil resistance I reported was exactly what the meter displayed, it was not precise. The next time I visit Ando I'll bring my better meter and report back
                        Last edited by ndutton; 02-12-2020, 09:45 PM.
                        Neil
                        1977 Catalina 30
                        San Pedro, California
                        prior boats 1987 Westsail 32, 1970 Catalina 22
                        Had my hands in a few others

                        Comment

                        • Ando
                          Senior Member
                          • Jul 2019
                          • 246

                          #13
                          Originally posted by ndutton View Post
                          I can add a little more information. On Sunday we performed a few basic tests:
                          1. Ando had already done a spark test. There was spark at the plugs but not of the highest quality. See item 6 below.
                          2. As Ando mentioned, compression test
                          3. We disconnected the fuel hose at the carburetor, put it in a container, jumpered the OPSS and turned on the ignition. The electric fuel pump clicked away as it should but zero fuel flow.
                          4. We removed the polishing filter to be sure it was neither clogged nor installed backwards. All good except no fuel in the filter.
                          5. We did a full timing exercise from scratch (the balloon compression stroke indicator is so cool). Timing and firing order are confirmed correct.
                          6. The coil is in poor physical condition (cracks and leaking around the top). Ando has a replacement MMI coil that he will install. We measured the primary resistance, 3Ω.
                          7. We set the idle mixture adjustment 1½ turns off the seat so it is ready for initial starting.
                          8. By the sound of the starter slowing down, the battery is anemic.

                          Our conclusions/project assignments at this time: replace the coil, test the fuel pump operation (done), find out why there is no fuel pumping from the on board tank and get better battery power either with charging or replacement.
                          I knew I failed to mention some of the things we did Thx, Neil. The balloon compression stroke indicator btw really IS sooo cool! The coil has been replaced. As soon as I get back to the boat, I will connect the fuel system to an external tank and run a test and luk what happens.

                          Comment

                          • Ando
                            Senior Member
                            • Jul 2019
                            • 246

                            #14
                            I attached the fuel system to an external fuel tank and after a few (ok, many) tries, it fired up. I’m very very happy. It sounds really nice. I then reconnected the actual fuel line and the motor started and continued to run. Dare I say that it miraculously fixed itself?

                            I then opened the thru hull valve and water was, let’s see what’s the word...”gushing” out? No but it seemed that way to me as the parent of this baby. After a barrage of morning texts to Neil (sorry buddy), I found the following thread and it helped clear up all my thermostat leak questions.



                            I hadn’t put permatex on the bottom of the gasket AND found that the nuts weren’t nearly tight enough. So I worked on those two things and am letting it sit for the day. Hopefully the issue is resolved when I go to start the motor tonight (with an open thru hull valve).

                            To be continued...

                            Comment

                            • Ando
                              Senior Member
                              • Jul 2019
                              • 246

                              #15
                              A couple other observations:
                              1. Exhaust fumes are emanating from the connection between the motor and the exhaust;
                              2. She doesn’t like it when I give her throttle; and
                              3. She doesn’t like it when I open the choke
                              She stalls out when I do #s 2 & 3

                              Comment

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