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Repowering a 54' Donzi Sportfish

Discussion in 'Donzi/Roscioli Yacht' started by DOCKMASTER, Sep 5, 2019.

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  1. DOCKMASTER

    DOCKMASTER Senior Member

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    Back to the Repower now........Port engine rigged in and coupled back to the the gear. We are doing final positioning on both engines and drilling tapping the mounting plates the resilient mounts sit on for final bolt down. I’ll post more pics once the engine room is cleared of all the shoring and rigging.
  2. DOCKMASTER

    DOCKMASTER Senior Member

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    Port Engine and gear:

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  3. Capt J

    Capt J Senior Member

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    Mapism was talking about ID also. The ID of the hose or pipe restricts flow far worse than what a fitting does. That is what I was getting at. If you had 3" all of the way from the intake to the inlet on the raw water pump and just the raw water pump had a 2.5" ID fitting it would restrict flow far less than if you had 2.5" all of the way from the inlet to the raw water pump. When speaking water flow and water pipes, most all piping is always measured in ID, not OD as wall thickness varies. Just go to Home Depot and look at the various piping.....copper, PVC, etc...….. pipes for non water flow are measured in OD. Anyways, enjoy, it should be fine. I personally would've gone larger to account for scaling, bends, etc...….. but as long as CAT agrees, you are good.

    When do you think you'll be done and seatrial? Seems like the project is moving right along.
  4. mapism

    mapism Senior Member

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    Far from focusing on that. If anything, the opposite.
    I only asked what the OD of the barb hose is, because from that follows the ID of the pipe that the engine manufacturer expected to be used.

    I appreciate what you are saying ref commonly accepted ways of measuring pipes, and I'm aware that NPS+schedule is an industrial standard (though not so much in EU as in the US).
    Also, when you say that this is what you deal with in the ship building and repair industry, I have no problem at all to take your word for it, because that is a sector I am not familiar with.
    On the other hand, I came across more pleasure boats shipyards than I can remember, and I can assure you that all of them bar none normally talk of sizes related to fluid treatment in terms of ID, regardless of NPS and wall thickness.
    And I mean that for all components: thru-hull fittings, valves, fittings, pipes for all sort of applications, like salt or fresh water, fuel, oil, exhaust, grey/black water tank... You name it.

    Just to make a practical example to better explain what I meant when I referred to the OD of the barb hose, check out this webpage.
    There are no less than 4 different versions of barb hoses, all compatible with the thread of a 3" valve (or pump intake, in your case), depending on the ID of the hose to be connected: 75, 76, 77, 90 millimiters.
    And yes, all of these sizes are referred to the ODs of the hose end in the fitting, but only because that's what relevant for the ID of the pipe to be connected.
    Now, the fitting that is typically used for a 3" raw water supply line is the one coded as "2156M*76", whose OD at the hose end is 76mm.
    And that matches perfectly a hose with an ID of 3", which everyone and their dog in the pleasure boat industry would call a 3" hose, regardless of the fact that it isn't, when you look at it in terms of NPS and schedule.

    But mind, I'm only trying to explain this just for sake of clarity, and there's no need to agree to disagree on the only point which really matters at the end of the day, i.e. whether your setup is OK for feeding enough raw water to your engines.
    In fact, while I would have used a 3" ID pipe for all the reasons I just explained, I also said in my last post that I don't think you are going to have any problem with your 2.695" ID pipes, considering also their length and material.
  5. rtrafford

    rtrafford Senior Member

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    As far as CAT agreeing, try to get something in writing. Protect that warranty.

    Two plumbs that I always oversize: raw water and fuel. One must consider not only optimal flow for the piping and the engines, but then consider the impact of the slight blockage from growth, debris, etc that will always occur. My project's intake requirement was 2.5". I went 3". Fuel was 5/8. I went 1". Let the bastards drink, and your problems will be elsewhere...
  6. mapism

    mapism Senior Member

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    Agreed, but that should be included in the normal process, as far as I know.
    I mean, the warranty validation of marine engines on newly built boats requires an official dealer to assist the builder upon first commissioning and sea trial, checking that dozens of engine parameters are within specs in the actual installation.
    And also anything that doesn't come with the engine but can affect its operation (typically, raw water and fuel supply, together with exhaust and e/r ventilation, must all be fit for purpose) should also be checked and validated.
    I don't see why it should be any different in case of a full repowering like the one which is being debated.
  7. DOCKMASTER

    DOCKMASTER Senior Member

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    You are correct MAPISM. The warranty validation is done at dock and sea trials. I've already been discussing with CAT. They have specific sensors they install and monitoring they do during trials. They have already stated after initial checks and validation they want to run at WOT for about 1.5 hrs. Holy cow I would never do that. But that is certainly going to tell us if all is well or not. And since I have the 5 year, 5,000/hr Platinum protection extended warranties you can bet they are going to make sure everything checks out as it is supposed to.

    We are still likely 2 months away from trials though. There is a ton of work to do to put the boat back together and you can only work so many things concurrently.
  8. rtrafford

    rtrafford Senior Member

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    That's radical. Fun if at sea. Run her to Bimini for lunch.
  9. PacBlue

    PacBlue Senior Member

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    Don't forget, everything is a little bit more expensive in Alaska :)

    But $8,000 per cylinder for a complete 100% Major Overhaul (A - Z) beyond just a long block should hopefully be the ceiling?
  10. rtrafford

    rtrafford Senior Member

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    While hoping the date of the need doesn't arrive soon (despite the use), I'm really a bit stumped right now as to whether or not I'd rebuild versus replacing.
  11. mapism

    mapism Senior Member

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    Positively +1!
    I'm well aware that running WOT for a meaningful amount of time is part of these tests, but 1.5 hours sounds indeed OTT.
    Btw, that's a whopping 180 gallons of fuel, according to Cat specs.
    Just a drop in the ocean of the total repowering costs of course, but a pretty expensive seatrial nonetheless...
    Best wishes in advance for enjoying the experience, anyway!
  12. Capt J

    Capt J Senior Member

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    1.5 hours at WOT????? I have done a 100 new engine start ups with CAT, never ever have I run wide open more than 10 minutes. The C 18 Acert pleasure rated engine, is rated to run WOT for an hour maximum in a day in the CAT book. Something is wrong with that request. Run at cruise for 1.5 hours yeah, WOT does not make sense.
  13. DOCKMASTER

    DOCKMASTER Senior Member

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    I'll get it sorted out with them. This was the first call and discussion about trials. I'll report back when we get closer and have a definitive plan.
  14. mapism

    mapism Senior Member

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    Any updates, Dockmaster?
    Tell me you are not going to put your project on hold.
    I'm now stuck onboard in Italy, with the whole Country fully locked down, and it's unlikely that the situation will improve quickly.
    So, I'm looking for as much boat porn as I can find!
  15. DOCKMASTER

    DOCKMASTER Senior Member

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    Sorry to hear you are stuck in Italy. Sounds like a pretty dire situation there.

    We are moving forward presently. Engines are in and preliminary aligned. Hoses and connections being made. Salon floor access cuts were epoxied in and glassed over. Aft bulkhead access cut is being fitted back currently. Still lots to do to put humpty back together again.

    Whereas I'm in Portland under a company mandated travel ban the boat and Repower crew are in Ketchikan where there have been no confirmed virus cases on the island. So for now the project continues. Of course we will not compromise anyone's safety and I suspect it will only be a matter of time before we face a broader shut down. But lots not turn this thread into a Coronavirus thread since we already have those.
  16. mapism

    mapism Senior Member

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    Yeah, that wasn't my intention of course.
    I already have plenty of opportunities to debate CV (even if just remotely) with many other folks, both in Italy and elsewhere in Europe!

    But thanks for your thoughts anyway, though my own situation is not bad, if I'm honest.
    Yes, movement restrictions are annoying, but here in Sardinia the situation is under control, and I'm onboard a 70 footer of a friend of mine, which for just myself and my wife is akin to living in a seaside villa!

    Back to the point, thanks in advance for your next post with pics, a boat porn fix will always be welcome from my part!
    And all the best for being able to complete everything before any broader shut down should become necessary - if any.
  17. DOCKMASTER

    DOCKMASTER Senior Member

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    All wiring and clean-up pretty much done in the main panel and behind. All the new systems (Gens, h2O Maker, block heaters, etc) all have new wiring all the way to their respective breakers. Additionally we cleaned everything, torqued all lugs and screws and checked every terminal connector. Yes, we found some loose ones, even a few that were never crimped and just had wires pushed in. Everything is now neatly banded up and well secured. All wires have printed floaters/tags and we have updated the original wire diagrams. The blue rotary switch in the middle of the panel is the selector switch between the 9k and 20k gens. We increased the wire size to both gens from original as well as the calcs showed original was borderline.

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  18. DOCKMASTER

    DOCKMASTER Senior Member

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    The access cuts in the salon are all epoxied and glassed back in. The aft bulkhead access cut has been refitted and glassed in. Doing final fairing and prep for paint.

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  19. DOCKMASTER

    DOCKMASTER Senior Member

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    The new 9k gen is on the new foundation and being final connected. This sits aft of the Port Engine above the shaft log and seal.

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  20. DOCKMASTER

    DOCKMASTER Senior Member

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    Engines all set, mounts tapped and bolted and in their homes. Note on Stbd engine we relocated the oil filters up and aft a bit as they were too tight inside the engine rail. Port side fit fine with factory mounts. Everything fits inside the engine rails and more room outboard too. We gained almost 7" of clearance on the front side which makes it nice since you have to go around from the front to access outboard.

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