Cal 29 Exhaust problem - galvanized section

Hi Listers, my 1970 Cal 29 has developed a hole the size of a quarter in the galvanized section of the exhaust just below the muffler. This entire galvanized section coming out of the manifold all the way to the rubber hose section is apparantly welded in one piece. Of course the boat is in the water Lake Ontario when I realized this - upon running it after launch - not noticed until it ran long enough for the thermostat to open. Tried to get the bolts off the piece holding galvanized section coming out of the manifold but they are going to need some major assist ie rust buster. The rest of the galvanized is quite solid and the man I had look at the problem said he could try a fix with a synthetic and some clamps. Or perhaps weld a new piece in place? Anyone got any wonderful ideas so I can sail the old gal soon? Shelley Richards Cal 29 #154 Seven Sister Wilson NY **************An Excellent Credit Score is 750. See Yours in Just 2 Easy Steps! (http://pr.atwola.com/promoclk/100126575x1221823249x1201398664/aol?redir=http://www.freecreditreport.com/pm/default.aspx?sc=668072&hmpgID=62&bcd=May ExcfooterNO62)

I don't have an atomic 4, but if my memory serves me, the exhaust fittings are all regular black plumbing fittings available at any supply house. Is this not the case? Wilkie On May 25, 2009, at 5:56 PM, sa… [at] aol.com wrote: > > > Hi Listers, my 1970 Cal 29 has developed a hole the size of a > quarter in the galvanized section of the exhaust just below the > muffler. This entire galvanized section coming out of the manifold > all the way to the rubber hose section is apparantly welded in one > piece. Of course the boat is in the water Lake Ontario when I > realized this - upon running it after launch - not noticed until it > ran long enough for the thermostat to open. Tried to get the bolts > off the piece holding galvanized section coming out of the manifold > but they are going to need some major assist ie rust buster. The > rest of the galvanized is quite solid and the man I had look at the > problem said he could try a fix with a synthetic and some clamps. Or > perhaps weld a new piece in place? Anyone got any wonderful ideas so > I can sail the old gal soon? > > Shelley Richards > Cal 29 #154 > Seven Sister Wilson NY > > > An Excellent Credit Score is 750. See Yours in Just 2 Easy Steps! > >

and why black versus galvanized? same on "Knot Ready" Reggie To: Ca… [at] yahoogroups.com From: wi… [at] mariposasailing.com Date: Mon, 25 May 2009 21:09:32 -0700 Subject: Re: [Cal_Boats] Cal 29 Exhaust problem - galvanized section I don't have an atomic 4, but if my memory serves me, the exhaust fittings are all regular black plumbing fittings available at any supply house. Is this not the case? Wilkie On May 25, 2009, at 5:56 PM, sa… [at] aol.com wrote: Hi Listers, my 1970 Cal 29 has developed a hole the size of a quarter in the galvanized section of the exhaust just below the muffler. This entire galvanized section coming out of the manifold all the way to the rubber hose section is apparantly welded in one piece. Of course the boat is in the water Lake Ontario when I realized this - upon running it after launch - not noticed until it ran long enough for the thermostat to open. Tried to get the bolts off the piece holding galvanized section coming out of the manifold but they are going to need some major assist ie rust buster. The rest of the galvanized is quite solid and the man I had look at the problem said he could try a fix with a synthetic and some clamps. Or perhaps weld a new piece in place? Anyone got any wonderful ideas so I can sail the old gal soon? Shelley Richards Cal 29 #154 Seven Sister Wilson NY An Excellent Credit Score is 750. See Yours in Just 2 Easy Steps!

According to some folks, when galvanized pipe is first heated, (as in an exhaust system), it releases poisonous fumes. Tom From: r good <my… [at] hotmail.com> To: ca… [at] yahoogroups.com Sent: Tuesday, May 26, 2009 6:24:21 AM Subject: RE: [Cal_Boats] Cal 29 Exhaust problem - galvanized section and why black versus galvanized? same on "Knot Ready" Reggie To: Cal_Boats@yahoogrou ps.com From: wilkie@mariposasail ing.com Date: Mon, 25 May 2009 21:09:32 -0700 Subject: Re: [Cal_Boats] Cal 29 Exhaust problem - galvanized section I don't have an atomic 4, but if my memory serves me, the exhaust fittings are all regular black plumbing fittings available at any supply house. Is this not the case? Wilkie On May 25, 2009, at 5:56 PM, sar0207@aol. com wrote: An Excellent Credit Score is 750. See Yours in Just 2 Easy Steps! Hi Listers, my 1970 Cal 29 has developed a hole the size of a quarter in the galvanized section of the exhaust just below the muffler. This entire galvanized section coming out of the manifold all the way to the rubber hose section is apparantly welded in one piece. Of course the boat is in the water Lake Ontario when I realized this - upon running it after launch - not noticed until it ran long enough for the thermostat to open. Tried to get the bolts off the piece holding galvanized section coming out of the manifold but they are going to need some major assist ie rust buster. The rest of the galvanized is quite solid and the man I had look at the problem said he could try a fix with a synthetic and some clamps. Or perhaps weld a new piece in place? Anyone got any wonderful ideas so I can sail the old gal soon? Shelley Richards Cal 29 #154 Seven Sister Wilson NY

--- In Ca… [at] yahoogroups.com, sar0207@... wrote: > > Hi Listers, my 1970 Cal 29 has developed a hole the size of a quarter in My Cal 2-27 with an Atomic-4 had a broken exhaust last season. I measured up the pieces (all 1 1/4 inch black pipe) along with some high temp pipe dope -- long ago, QShicks recommended Rector-seal -- and some steam pipe fiberglass insulation. The hardest part was getting everything to come apart -- I had replacements for every piece except the elbow where the water is injected. Long soaks in Kroil, and two or three foot long cheater or breaker bars - pipe wrenches, and mild cursing seemd to do the trick. Highly recommend that you remove as much as you can and work on it at home where you can stand up -- I don't think the 'cave' is a very good place to work on an exhaust system. I took the exhaust manifold off as well, so I could clean everything up as I could not remove the nipple from the exhaust flange... I think I have pictures, if anyone is interested... Even with black pipe, you will have fumes from the oil, fiberglass and what not. And if you have a insulating wrap that looks like it might be asbestos, assume it is. Wear a respirator, spritz it down with soapy water (keeps it from getting airborne) and double plastic bag it. If you know it's asbestos, you have to dispose of it properly (hazmat) Best of luck Shelley, Harold

--- In Ca… [at] yahoogroups.com, sar0207@... wrote: > > Hi Listers, my 1970 Cal 29 has developed a hole the size of a quarter in My Cal 2-27 with an Atomic-4 had a broken exhaust last season. I measured up the pieces (all 1 1/4 inch black pipe) along with some high temp pipe dope -- long ago, QShicks recommended Rector-seal -- and some steam pipe fiberglass insulation. The hardest part was getting everything to come apart -- I had replacements for every piece except the elbow where the water is injected. Long soaks in Kroil, and two or three foot long cheater or breaker bars - pipe wrenches, and mild cursing seemd to do the trick. Highly recommend that you remove as much as you can and work on it at home where you can stand up -- I don't think the 'cave' is a very good place to work on an exhaust system. I took the exhaust manifold off as well, so I could clean everything up as I could not remove the nipple from the exhaust flange... I think I have pictures, if anyone is interested... Even with black pipe, you will have fumes from the oil, fiberglass and what not. And if you have a insulating wrap that looks like it might be asbestos, assume it is. Wear a respirator, spritz it down with soapy water (keeps it from getting airborne) and double plastic bag it. If you know it's asbestos, you have to dispose of it properly (hazmat) Best of luck Shelley, Harold

I also had to replace the exhaust on my 2-27 that has the Universal 5411 last year. Since it cracked through the threads, I used Sch 80 pipe for the replacement so there would actually be some metal left where the threads are cut. I also searched for all domestic pipe elbows and nipples (ie no BORG, either color). The longest section was not a standard length nipple and I had a mechanical contractor make if for me. I never got the nipple out of the exhaust flange so I replaced that as well. I used 2 layers of header wrap to insulate the pipe. As far as the existing insulation is concerned, fiberglass is just as bad for your lungs as the a-word so be careful regardless. If you think it is the a-word, I believe there are legal ways of disposing "consumer" quantities of the stuff so check your local regulations. And yes, it did stink and smoke until the header wrap was "cured" and the oils had burnt off the pipe, so you will want to run it with as much ventilation as possible. Bob Ellison 2-27 Après Ski ----- Original Message ----- From: haroldbeer To: Ca… [at] yahoogroups.com Sent: Tuesday, May 26, 2009 2:24 PM Subject: [Cal_Boats] Re: Cal 29 Exhaust problem - galvanized section --- In Ca… [at] yahoogroups.com, sar0207@... wrote: > > Hi Listers, my 1970 Cal 29 has developed a hole the size of a quarter in My Cal 2-27 with an Atomic-4 had a broken exhaust last season. I measured up the pieces (all 1 1/4 inch black pipe) along with some high temp pipe dope -- long ago, QShicks recommended Rector-seal -- and some steam pipe fiberglass insulation. The hardest part was getting everything to come apart -- I had replacements for every piece except the elbow where the water is injected. Long soaks in Kroil, and two or three foot long cheater or breaker bars - pipe wrenches, and mild cursing seemd to do the trick. Highly recommend that you remove as much as you can and work on it at home where you can stand up -- I don't think the 'cave' is a very good place to work on an exhaust system. I took the exhaust manifold off as well, so I could clean everything up as I could not remove the nipple from the exhaust flange... I think I have pictures, if anyone is interested... Even with black pipe, you will have fumes from the oil, fiberglass and what not. And if you have a insulating wrap that looks like it might be asbestos, assume it is. Wear a respirator, spritz it down with soapy water (keeps it from getting airborne) and double plastic bag it. If you know it's asbestos, you have to dispose of it properly (hazmat) Best of luck Shelley, Harold

I have done this fix several times, each time I have modified to some extent. First, I assume you no longer have one of the original jackets stand pipes that were used for the exhaust, but a water lift muffler. The easiest method is to purchase a new exhaust flange. They are available at Moyer Marine. The also have some drawing available that contain the recommend pipe lengths and height. This is very important for the water inject point. You may get lucky and find out you cean cut don on the section of dry pipe. Do not assume the current system is prefect. You can also get the needed injection point from Moyer Marine. They have a hose barb that is welded into a 1 1/4 pipe that works really well. The system is built with 1 1/4 inch pipe. I have use black, galvanize and stainless pipe. My current system uses stainless, which is not tapered pipe thus it does not stay tight. If I did it a gain I would go back to black pipe. The flange is another issue because it is not tapered. I have seen nipple that goes into the flange welded in place. Then you assemble the pipes and connect the hoses. After that you wrap it with a insulated clothe to contain the heat. This critical in the dry section of the system. Moyer Marine also sells the wrap. I highly recommend the Moyer Marine Atomic 4 manual if you do not have it. Good luck. If you need more info email me. Brent J --- In Ca… [at] yahoogroups.com, r good <my1972ih@...> wrote: > > > and why black versus galvanized? same on "Knot Ready" > > Reggie > > > > To: Ca… [at] yahoogroups.com > From: wilkie@... > Date: Mon, 25 May 2009 21:09:32 -0700 > Subject: Re: [Cal_Boats] Cal 29 Exhaust problem - galvanized section > > > > > > > > > > > > I don't have an atomic 4, but if my memory serves me, the exhaust fittings are all regular black plumbing fittings available at any supply house. Is this not the case? > > > > > > Wilkie > > > On May 25, 2009, at 5:56 PM, sar0207@... wrote: > > > > > > > > > Hi Listers, my 1970 Cal 29 has developed a hole the size of a quarter in the galvanized section of the exhaust just below the muffler. This entire galvanized section coming out of the manifold all the way to the rubber hose section is apparantly welded in one piece. Of course the boat is in the water Lake Ontario when I realized this - upon running it after launch - not noticed until it ran long enough for the thermostat to open. Tried to get the bolts off the piece holding galvanized section coming out of the manifold but they are going to need some major assist ie rust buster. The rest of the galvanized is quite solid and the man I had look at the problem said he could try a fix with a synthetic and some clamps. Or perhaps weld a new piece in place? Anyone got any wonderful ideas so I can sail the old gal soon? > > Shelley Richards > Cal 29 #154 > Seven Sister Wilson NY > > > > > > An Excellent Credit Score is 750. See Yours in Just 2 Easy Steps! >