Another electric FWC system installed

[ndutton]

Here are a few pics of Kalina's new FWC system with electric circulation pump.

It would have been much easier to spring for the Moyer kit rather than driving all over creation to gather up the parts but unfortunately in my case the Moyer system would not work. Besides having a Catalina 30 with zero room in front of the engine for a PTO pulley, I also have a water heater mounted higher than the engine. Soooo, hello electric coolant pump and header tank.

Here's a drawing of my system

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Here's the heat exchanger in place. Note that the hoses are color coded, black for the coolant circuit, red for raw water.
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and the electric pump. The clear hose is so I can see the coolant.
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The header tank and recovery bottle are located under the V berth adjacent to the water heater
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it's normally not visible
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Continued on the next post due to picture limitations.

[ndutton]

Electric FWC continued

Here's the engine compartment, getting pretty full in there. Note the reversed manifold plumbing.
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And upon completion, two toasts: one to the previous owner and one to this group. Without you guys this would not have happened.
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[hanleyclifford]

Neil - What type of pressure cap did you choose for the header tank? Very neat workmanship! Look out, Jerry!

[ndutton]

One more detail

With electric FWC, one area in need of thorough cleaning and (IMO) modification is the sideplate diverter Tee and water jacket. I enlarged mine to 1/2" NPT and routed the coolant hoses around the front of the engine leaving the back of the engine for the raw water hoses.

I broke one of the mounting bolts removing the cover so I installed stainless studs with Loctite instead, figuring I'd rather have the fastening nuts outside the water jacket. If the studs get frozen in place, so be it, don't care anymore.
[ATTACH]4718[/ATTACH]

Here are both sides of my modified sideplate. Note the new, larger alternator bracket that spans two bolts rather than one to spread the load.
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Here it is with the coolant hoses plumbed
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[ndutton]

Neil - What type of pressure cap did you choose for the header tank? Very neat workmanship! Look out, Jerry!

For now I have a 7 lb. cap but I'm looking for a 4 lb. My comfort zone is:

1. Don includes a 7 lb. cap with his kit.
2. My water jacket appears to be in really good condition.

With the sideplate off I poked and vacuumed up as much crud as possible (wasn't that much to my surprise but then I recently acid washed the system), then water jetted the remainder, got it really clean.

[TomG]

Great looking work, Neil.

Thanks for posting.

[hanleyclifford]

Nice treatment on that side plate. The studs make a lot of sense avoiding removal and possible block damage every time the plate comes off. That alternator bracket is another breakthru.

[ndutton]

Nice treatment on that side plate. The studs make a lot of sense avoiding removal and possible block damage every time the plate comes off. That alternator bracket is another breakthru.

Can't take credit for the bracket, copied it from someone else. I should have mentioned I used brass nuts on the stainless studs so if something wants to lock up solid, the softer hex nuts are sacrificial.

[13jeff13]

Very Nice work Neil.

I am a little curious what the temperature differential will be between the RW intake and the temp at the injection point at the exhaust input. A lot cooler than what it was previously I would assume?

[thatch]

Neil,
I'm sure that there will be a lot of "applause" when the "early to bed", East coast folks see your post, so I'll get my cheer in now. You have truly done a textbook job of design engineering and execution on your system.
Bravo, Tom

[ndutton]

Well thanks Tom (both Toms)

It remains to be seen if it works. I have yet to fill 'er up with coolant (conflicted on the type) and start testing, IR thermometer at the ready.

Coolant conflict
I have a variety of metals in my system: A-4 alloy iron, brass, stainless, copper and aluminum. I want the benefit of rust inhibiting properties of ethylene glycol but don't want to eat up vulnerable metals. Safer propylene glycol has a reputation of organic slime, less to no rust inhibitors and limited life. Looks like once again, life is a compromise. It's never clear cut and simple. I need to decide by tomorrow.

[Dave Neptune]

Cap

Hanley, why not a "O" preassure cap. I have had need of running with no praessure in a few instances. What I did was take a functiong preassure cap and drilled a 1/8 inch hole in it. It still sealed so the coolant level was maintained but without preassure. Might be what you are looking for.

Regards Dave Neptune

[roadnsky]

...Very neat workmanship! Look out, Jerry!

Ahhh, does my heart good to see it!
Very nice Neil!

[hanleyclifford]

Hanley, why not a "O" preassure cap. I have had need of running with no praessure in a few instances. What I did was take a functiong preassure cap and drilled a 1/8 inch hole in it. It still sealed so the coolant level was maintained but without preassure. Might be what you are looking for.

Regards Dave Neptune

I had an 8 lb cap and I just cut away about 2/3 of the spring. The most pressure I've ever seen on the system is 2 lbs and did not loose any coolant.

[sastanley]

Neil, looks great!

Lots of things folks like me may want to copy when we do our FWC conversion!