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  #1   IP: 24.152.131.220
Old 03-05-2011, 10:09 PM
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Another electric FWC system installed

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

Here's the heat exchanger in place. Note that the hoses are color coded, black for the coolant circuit, red for raw water.
FWC HX.jpg

and the electric pump. The clear hose is so I can see the coolant.
FWC Electric Pump.jpg

The header tank and recovery bottle are located under the V berth adjacent to the water heater
FWC Header Tank Under V Berth.jpg

it's normally not visible
FWC Header Tank Concealed.jpg

Continued on the next post due to picture limitations.
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prior boats 1987 Westsail 32, 1970 Catalina 22
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Old 03-05-2011, 10:15 PM
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Electric FWC continued

Here's the engine compartment, getting pretty full in there. Note the reversed manifold plumbing.
FWC Engine Compartment.jpg

And upon completion, two toasts: one to the previous owner and one to this group. Without you guys this would not have happened.
FWC A Toast to the Project.jpg
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prior boats 1987 Westsail 32, 1970 Catalina 22
Had my hands in a few others
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Old 03-05-2011, 10:25 PM
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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.
FWC Sideplate Studs in Place.jpg

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.
FWC Sideplate w new Alt Bracket.jpg
FWC Diverter Cap.jpg

Here it is with the coolant hoses plumbed
FWC Sideplate Plumbed.jpg
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prior boats 1987 Westsail 32, 1970 Catalina 22
Had my hands in a few others
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Old 03-05-2011, 10:33 PM
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Great looking work, Neil.

Thanks for posting.
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Old 03-05-2011, 10:53 PM
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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?
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Old 03-05-2011, 11:21 PM
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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
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Old 03-05-2011, 10:34 PM
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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.
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Old 03-05-2011, 10:38 PM
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Quote:
Originally Posted by hanleyclifford View Post
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.
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Old 03-05-2011, 10:21 PM
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Question

Neil - What type of pressure cap did you choose for the header tank? Very neat workmanship! Look out, Jerry!
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  #10   IP: 24.152.131.220
Old 03-05-2011, 10:29 PM
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Quote:
Originally Posted by hanleyclifford View Post
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.
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1977 Catalina 30
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prior boats 1987 Westsail 32, 1970 Catalina 22
Had my hands in a few others
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Old 03-06-2011, 06:01 PM
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Quote:
Originally Posted by hanleyclifford View Post
...Very neat workmanship! Look out, Jerry!
Ahhh, does my heart good to see it!
Very nice Neil!
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