Repower 2004 AR210 with MR-1 HO's

[84rzv500r]

here's your problem lady... bad news i dont have enough new parts for convert over to the high pressure pumps yet... good news I had enough used parts from the junk pile and new parts to repair the starboard low pressure pump...

SBT shaft on its way out again see the cracks... no water in the housing and no rust looks like they got hot and cooked.... had a OEM shaft, impeller assembly that the stator was a little beat up and it will cavitate a little but its better than not using the boat...

SOLAS Stainless impeller housing had some casting porosity but otherwise unharmed... cant say as much for the SOLAS concord 12/18 impeller its toast.... 0.045 clearance anyway....

and who all back together this time filled with synthetic 80W-90 gear oil and a dollop of waterproof bearing grease

note to self: 4 years is too long for a service interval will build two sets of high pressure pumps and inspect them every two years or 600 hours which ever comes first.

 

[84rzv500r]

Welcome back my friends to show that never ends... (The Who) The last few parts are starting to show up to build the 155mm HO pumps (i was calling them high pressure as they use a 20mm larger hub diameter and a different tail cone to produce more pump pressure)

Ill build a couple prototypes from my spares pile... Im gonna build 8mm x 1.25 x 205mm 316L stud kits so ill prolly have to touch all the holes on the mill but for the HO stator housings i'll need to move the bolt centers in just a bit but easy peasy... then tap and plug the coolant hole to the casting and pop a fitting in the cap for the coolant screen housing... the 11/20 impellers spinning up then we should get some speed back eyeball engineering was pretty close...

 

[84rzv500r]

new thought ill bet can get/make a press fit piece of aluminum and just epoxy into the existing hole

 

[84rzv500r]

update as new clean parts roll in... easy peasy machine work... and make some beefy 8mm 316L stainless studs.. I think now that I've had a chance to look at it I think ill just make some light press fit plugs 6061 plugs for the cooling water hole put the casting in the oven at 200 and the plugs in the freezer and tap tap done... plenty of meat in the HO casting for the two new stud holes...

 

[84rzv500r]

put another 2 hours on the boat Friday and Saturday.... as to be expected with the junk stator I used to fix the stbd pump there's a bit of cavitation out of the hole and it still cavitates horribly over 9000 but though it cruses fine at 25-40 mph... headed out today for sunday funday BBQ and JAM session...

 

[84rzv500r]

work on the prototypes begins...

 

[84rzv500r]

ok i had the 8 x 1.25 die to make the studs.. and a good selection of ball end mills here in FL however I had to order drills and NPT taps to mod the stator housings, ordered 316L stainless NPT plugs and NPT to barb 90's... I cant wait to get the raw water screens and HO pumps and correct impellers...

 

[84rzv500r]

just ordered some 1/2 NPT 6061 weld in bungs... looking at the cover i think this best as they saw fit to gusset the flat area of the strainer cover... and there is a bit less that 1/8th thickness there to thread... it's not a pressure thing its having enough threads to seal...

 

[84rzv500r]

I guess before all my new marine mat gets here next week i need to make the seat cushions for my bench seat hatches... 32 x 14.5"...
so time to dig through the parts room and find the HDPE Sheet, 1.25 neoprene closed cell foam, vivid white marine vinyl, 316 stainless staples and the 316 stainless 1/4-20 Tee nuts and flat head bolts...

I did steal a part off the dead jetski to make a boarding ladder for a friend who hurt his back... cut to size and welded in a 12" piece of 1" schedule 40 aluminum pipe and coated it with non skid compound...

first time ever with a spool gun for aluminum... had to rob some argon from the tig welder tank... all I can say is WOW.... and FAST !!!! gonna order a pipe and tubing bender and a bunch of 1" and 1.5" sched 40 6061 or 6063 aluminum pipe... I have alot of plate already...

 

[84rzv500r]

gettin hot... banged out the cushion bases and drilled the mounting holes... it will end up being a 3/4" thick two layers...1/2 and 1/4" Expanded PVC for the seat bases... as I didn't have enough 1/4" HDPE... oh well... I'll cover them tomorrow morning as its time to load up the boat and head out for Sunday funday... oh and you may ask why there is a space at the outside edge of each cushion and im gonna have enough extra marine mat... to cut a piece to fill the two small cut outs on the outside of the bench seat back and the outsides of the cushion... just a detail to tie it all together it dont look so hacked together...

 

[84rzv500r]

wow the Marine Mat showed up today as well as my new console storage hatch doors from ... I believe there are direct replacements for the OEM doors that are disintegrating... More on this later.... point of note Yamaha appears to source nearly all of the deck and hull fixtures from the US market...

cant wait to get this old mat torn off and get my new marine mat installed.

Im also raising my Bimini about 3" so I don't bump my bald head on it so much... I'll post on that shortly as well..

https://www.westmarine.com/tempress-11inch-x-15inch-cam-latch-hatch-7inch-x-11inch-hatch-opening-white-1954908.html

 

[84rzv500r]

Bimini ideas and marine mat...

 

[84rzv500r]

finished up the bench seat cushions... as you can tell im a function over form kind of guy.. so it aint perfect however there are no seams and I used closed cell neoprene foam so it cant get waterlogged... and I switched from HDPE to Expanded PVC sheet its 3/4" thick 1/2 + 1/4 and all 316 stainless fasteners... we'll see how it holds up..

it needs a good cleaning...

 

[84rzv500r]

bimini extensions worked great... new hatch doors... and a weather cover for my head unit... got a lot of small jobs done today... just have to clean up and flush the engines as she gonna be out of the water for a few days as this himacane passes...

oh and in previous episode I did reinforce the ABS around the radio cut out with more ABS... M.E.K. is a solvent for ABD and it works really easy...

 

[84rzv500r]

Marine Mat Prep deck for install... this is a bit ugly getting that old dark grey mat off... tried heat gun... no dice... so i just pealed it off slowly and then hit it with the pressure washer... better but that black sticky stuff gets every where... so i soaked it in acetone and then used acetone and a stiff bristle veggie brush and then hit it with the pressure washer and it came right off and the water mixing with acetone seems to make it ball up in to a non sticky form... oh and it also takes the white paint off the stainless steel hinge LOL

 

[HangOutdoors]

Marine Mat Prep deck for install... this is a bit ugly getting that old dark grey mat off... tried heat gun... no dice... so i just pealed it off slowly and then hit it with the pressure washer... better but that black sticky stuff gets every where... so i soaked it in acetone and then used acetone and a stiff bristle veggie brush and then hit it with the pressure washer and it came right off and the water mixing with acetone seems to make it ball up in to a non sticky form... oh and it also takes the white paint off the stainless steel hinge LOL

View attachment 189044View attachment 189045

Consider using DeBond if you need to go through that again. Takes it right off all othe adhesive comes off easily.

 

[84rzv500r]

Consider using DeBond if you need to go through that again. Takes it right off all othe adhesive comes off easily.

thanks I just ordered a couple cans!! I have the whole cockpit left to do... boats are endless work however im done working for today cause its getting HOT out and I'm going Yachting...

 

[HangOutdoors]

just be careful where you spray it, it will work on 4200 -and 5200 as well as all other caulks and adhesives. I made the mistake once

 

[Russell]

I used WD40 on my left over sticky/Sea Deck. That in combination with many Terry cloth rags to get that sappy slime off the floor.

 

[84rzv500r]

well Ive resisted putting tower speakers on my boat however idle hands do the devils work...

now I just need a place to put them