[wagner]

Hello Aftourians,

By way of update, the engine swap has been a success!

The mechanic (me) was able to get the new engine running well on the pallet and set his sights on removing the existing a4 from the boat (sabre28-1). Using an 8” puller, he torched and quenched the prop and shaft and it came off after extracting appropriate penitence from the mechanic. The mechanic uttered a jubilant “yawp” when the piping hot prop popped off.

With the prop off, the engine slid forward without to much trouble. As an added bonus, the stuffing box and its hose came with it, coming detached from the tube. The mechanic recited prayers of thanksgiving that the stuffing box and hose had not detached under other circumstances. The stuffing box on this particular vessel has been written about at length on this forum under the previous previous owners care. It is unclear that the stuffing box had been serviced since that time. Two wraps of packing material remained.

The shaft coupler proved now to be as stubborn as others have suggested. Torch and quench, pb blaster and general banging yielded little results other than blasphemy and newly invented curses. The next day saw a grinder and a chunk of mineral wool (to catch sparks) come on board. The mechanic used the grinder to cut two slots in the joint between the drive and shaft couplers and to create two metal wedges using two slotted screw drivers. With the wedges, the shaft and coupler came off and another prayer of thanksgiving and repentance (for the curses and blasphemy) was offered.

The rest of the swap proceeded in a manner similar to what is described above: new coupler, shaft and prop to machine shop ($350 at Rose Marine in Gloucester); pump out oil on existing engine; small crane ($300 Clay Sign Service) to lift out old engine and lift in new engine. Engine install took approximately 6 hours once in the boat. The hardest parts were attaching the coupler to the engine, bolting on the exhaust flange (more innovative curses and invocation of divine condemnation), and bolting on the shift linkage bracket.

The engine refuses to idle super low, but this appears to be a carb adjustment issue that can be dealt with.

Otherwise, this adventure has been quite enjoyable and successful, with a reliably running motor now in the boat. Sea trials were conducted by the mechanic and a co-owner on a 6 mile motor sail in Salem Sound in 15-20 gusting 25+, rain and 6-8’ sea. Two reefs in the main and half the Genoa. Asides from the high idle, the motor ran flawlessly at 150-170 degrees and about 40 psi of oil pressure.

It could not have been done without the active and passive help of this forum and its tireless contributors. Truly, you gentlefolk make this forum one of the most helpful, pleasant places on the internet.

The mechanic now looks forward to starting an new overhaul/rebuild thread for the old A4.