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Generator Parts Needed - Heat Exchanger

  • Thread starter Thread starter Kim Beatley
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Kim Beatley

Kim Beatley

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Oct 6, 2010
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  1. OWNER - I own a Hatteras Yacht
Hatteras Model
36' CONVERTIBLE-Series I (1969 -1977)
I have a 7.3 KW QuickSilver, (sold under the Mercury Name, but manufactured by Generac), generator that runs, (ran) great. The heat exchanger is now leaking and needs parts, ,mixing chamber for exhaust and water, gaskets, bolts, etc. I have the catalogue sheets and parts numbers for both Mercury and Generac, but cannot find a source that has the parts. Apparently this generator has not been manufactured in a number of years.

Would welcome any ideas on where to find parts.

Thanks

Kim Beatley
PV23
 
I know a guy that had one of those in a 42' Bertram. He'd haul it out from under the cockpit deck every year and paint it to keep it from rotting. Anyway, he mentioned to me that they only made it for a year or two. So I'm thinking parts are going to be a little tough to find.

Maybe go to a heat exchanger maker and see if you can match it up?

http://sen-dure.com
 
Ha ha ha ha. I got one too! But in diesel (8.0) so its even more of an orphan. You'll probably agree when I say that every single peripheral part put onto these machines was a complete piece of shiit. Funny enough the engine from isb shubera and the generator end are quality parts. Getting to the point I may have purchased the very last heat exchanger end caps available two years ago. I searched everywhere and really got on people's nerves to look through old stock but I finally found them. I did the sen-dure route but they have nothing that matches up. I will go through my notes and find the company that I bought the parts from because they still have some that will help you. They have gaskets, sensors, etc. I even did research for them and figured out what the exhaust overtemp sensor was because they didn't know and now they carry it. I'll post the name of the company later today. What you can do and what I did with the new heat exchanger end caps was to encase them in LOTS of epoxy because as you know the morons made them out of cast iron coupled with a heat exchanger body of aluminum and cupronickel heat exchanger element. A poor design to say the least. If I wasn't able to obtain the new end caps I had an alternative plan that was to take flat stock stainless and weld piece of stainless tube onto it and another piece of flat stock on the end. This would have created a new end cap of different dimensions but functionally the same. It can be done for both end caps even though they are slightly different. Again, these quicksilver generators are best suited as mooring blocks but with only three hundred hours on it I wasn't ready to do that.
 
Guess what! I have one also since 1999, with 3500 hrs on it. It's 8KW diesel. The engine still original, but the generator rotor had been repair. The only compliant I have is the heat exchanger caps. I have to replaced them like every 3 years. And the cost of them is too high right now. Like $1,000 for both ends. Right now I need to replace them again, I am planing take both ends to a maching shop to see if they can make them out of s/s. I would let you know. What, did you do with yours? Thanks! Jerry
 
Hi Jerry The end caps are certainly a very weak link in this design. The original end caps were in bad shape when I opened the heat exchanger for the first time. There was an actual hole that didn't leak simply due to all the corrosion on the back of it. when I bead blasted the end caps it became apparent how bad they were. what I did with this first set was to braze the hole as best as I could, then filled with a thickened epoxy. once that was set I coated the entire inside surface of the end caps. this repair worked well and I still have them as templates or something...you know, you just cant throw away boat stuff! I did find new end caps and I also purchased a whole bunch more of the cast iron parts while I was buying. knowing that the same fate was in store for these parts I decided to repeatedly dip them in regular west system epoxy. I coated all sides and just let the epoxy fill all the threads and bolt holes until I felt it was thick enough. once it was cured I simply drilled out the bolt holes, retapped the threaded holes and sanded the mating surface smooth. I have been running the epoxied parts since spring 2009 and no issues yet. the heat exchanger in my set up anyway self drains so I believe my epoxy coating should last for some time. I do believe that fabricating the entry cap wouldn't be much of an issue however the outlet side is a bit more complicated. you say the caps are about 1000 now. is that reissued parts or the last of the remaining stock?
 
Just thinking out loud here, but you're only talking about 13hp or so and unless there is something especially peculiar about this set up, there must be dozens of heat exchangers that are of better quality that could be employed with a little creative thinking. That way you might avoid the Ground Hog Day phenomenon. Just saying...
 
Hi! Bostonhatteras, I can still find this heat exchanger end caps, $1200, for both ends. I going to take the generator out for maintenance next moth. If they are not, to bad, I will try your epoxy idea. If they are in bad shape, I will try the Maching shop. I would let you know. Thanks, Guys for yours ideas. Jerry
 
Guys.... After an exhaustive search for my heat exchanger parts, I found them all on line.... but as the post before state, really expensive.

I ordered all but the end caps on line, total was $800. I took my old end caps to a local machine shop and within a week, had two new ones, milled out of stainless for a total of $300. What a deal... They must have used a laser to scan and then clean up in CAD and then send the file to the milling machine They fit perfect.

Back on line now and running well. If you want me to have your caps machined, call me.. 804-684-5999. No promises on price, but they did a great job for me.
 
Kim Beatley said:
Guys.... After an exhaustive search for my heat exchanger parts, I found them all on line.... but as the post before state, really expensive.

I ordered all but the end caps on line, total was $800. I took my old end caps to a local machine shop and within a week, had two new ones, milled out of stainless for a total of $300. What a deal... They must have used a laser to scan and then clean up in CAD and then send the file to the milling machine They fit perfect.

Back on line now and running well. If you want me to have your caps machined, call me.. 804-684-5999. No promises on price, but they did a great job for me.
Click to expand...

Hello! I took the Generator, heat exchanger, caps, out, two weeks ago. Both ends, were completly bad. I order both again (1000.00):mad: And apply the epoxy coating on both of them. I did not see you thread until now. I will call you, if, is OK, with you, to see if you can provide me with the contact number of the machine shop. Thanks Guys!
 
By all means call. I sent you PM with number
 
I'm kinda late to the game here, but I just saw the thread. FWIW, I have a heat exchanger off an Onan MDJE 7.5kw diesel genny. If you could mount it remotely and run hoses to it to make it work, you're welcome to it. All I want is shipping cost and maybe a cheap bottle of Cab.
 
Hi,I know this is an old thread, but I am trying to reach out to get in contact with the machine shop that made the stainless ends for the heat exchanger for the member above. Tried email and pm, not sure if they are still an active member. I have a QS 7.5 and need new heat exchanger end caps. Would prefer not to buy the cast iron junk from generac. Anyone who has any info on this I would greatly appreciate it.Thank you,Brad Harbold410-688-3798
 
I think the OP is on an extended stay overseas, but any machine shop should be able to make something up especially if you can make drawings for them.
 
I am sure any machine shop can make them. What I was trying to do was eliminate the cost of doing all the cad work if a shop exists out there with the file already in house. Not to mention expediting the process

Thanks,

Brad
 
Sorry to waste your time. :rolleyes:
 
btharbold said:
I am sure any machine shop can make them. What I was trying to do was eliminate the cost of doing all the cad work if a shop exists out there with the file already in house. Not to mention expediting the process
Click to expand...

You know there are real machinist that can make something without using CNC or needing a CAD drawing?
 
Guys I know any decent machinist with a bridgeport can make these parts. I was looking to find the above referenced shop that had the design work done. At $300 or whatever that shop might charge now, thats a steal. Local machinists have quoted me around $1k to make both parts copying the originals via lathe, milling machine etc using the conventional ways. If a shop has a CNC and can put in a blank and run an existing program... Time is $$.

Sorry to have bothered everyone.
 
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