rwaterman

Catalina 30 Muffler Replacement

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Anyone out there ever had to replace the water lift muffler in a Catalina 30?  We have a 1985 boat and the muffler appears to be leaking; mixing elbow is suspect too.  It looks like the boat was built on top of the engine and exhaust.  Do you have to remove the galley to get it out?  Will it somehow fit out of one of those little access openings?  Any issues with getting the exhaust hose off?  I want to keep the exhaust hose going out (it;s fairly new), anything else can be cut.  All advice welcome; thanks!

Rob W.

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Have you spoken to Catalina? They are famous for their customer support.

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The galley cabinet will come out and provide more space.  I just completed an engine replacement in my Cat 30.  Unfortunately I didn't pull the water muffler - I just reused it.  I assume you had the original muffler which was fiberglass. If it is, indeed, leaking from a crack or pinhole you could consider just repairing it with some glass and resin.  

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As mentioned, removing the galley makes it easier.  I had 1975 hull #91 and had the engine out a few times and also replaced the water heater which was under there as well.  Mine had a big metal onan generator muffler which I replaced with a small fiberglass one.    I got good at getting the galley out.

Good boats and you can still get the catalina folks to talk to you about issues / projects.

--Kevin

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Thank you all!  I don't know why it didn't occur to me to call Catalina, duh.  I have heard for years that their customer service is amazing.  Galley removal looks like a real PITA but if it's gotta be done so be it.  Thanks again.

 

Cheers

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rwaterman, I removed the galley to have good access to the engine. It has several but not many sheet metal screws holding it to the top of the engine box. I have an older boat ('77), so I do not know if they made changes that far down the road in construction techniques..There were a few screws up near the shelves too.

You can probably do this work without removing the galley, but it will get in the way.. The first time I removed the galley, I had it out all winter...Now it is a 30 minute job if I want to remove it.

Even though you likely have a diesel, Moyer Marine has a nice stainless waterlift that should work...It is pricey though. I have an Atomic4 in my boat, and I am using a Vetus muffler. Which motor do you have?

tiz, any pics of the water heater in there? My boat (#511) didn't even have pressure water..it has that now, but I'd like to add hot for a head rinse off, or things like washing dishes.

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'Bitches - 

Sorry but probably no pictures.  I got the boat in 86 and sold it in 96, so it was a while ago.
I recall the heater as a white fiberglass housing but probably any small ~6gal water heater would work.  The way it was arranged was:

engine on centerline

outboard and aft (under galley) was the muffler (onan type changed to small f/g "can")

fwd of the muffler was the batteries - also next to engine

outboard of the muffler and batteries was the water heater.

There were little wood platforms glassed to the hull for the muffler, batteries and water heater to acommodate the hull curve. 

We never had particularly hot water since the a4 was raw-water-cooled and set up to run on the cool side to prevent salt buildup in the water jackets.

--Kevin

 

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Thanks for the reply. I've relocated my batteries to stbd and converted the old A4 to FWC, so I have some room to work with and some heat.. I've been thinking about using the antifreeze loop to add a simple inline HX (like an oil cooler from a big diesel) that I can run as 'on-demand' for hot water instead heating up 6 gals worth. One less major "system" to deal with.

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Do insulate the hot water line to the head sink/shower.  It's a long way and there's lots of loss in the plastic tubing on the way there.  The galley sink will be fine.

Especially with that sort of heat exchanger setup, where the rate of rise in temp may not be that much.  Also, you'll have to have engine running and warmed up for hot water every time.

We eventually used solar showers very happily, mainly to save on water.  But they work great and may solve the entire problem for you.

 

 

 

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Roger all that. I currently hang a Sun Shower on the forward lower and send the hose thru the window, which works pretty well. Understood the engine would have to be running for hot water, but I think that an on-demand type system would be more efficient than heating a 6 gallon box.

Did not mean to sidetrack the discussion..rwaterman..the engine was installed before the galley. You can work around it, but it is not too much work to remove it.

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Thanks Hike!  I'm going to move the galley out of the way.  Actually my biggest concern is how to get the exhaust hose off the top of the old muffler, not much space under there to wrestle with it.  

Cheers,

Rob W

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Yeah..it seems a bit daunting at first, but if you are like me, once you remove the galley, you think about all the other stuff you could do while it is out.

port_side_before.JPG

port_side_after.JPG

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Alca, thanks. I'll look into them..I think you are right..like an oil cooler or something!

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Thanks for the encouragement Hike!

I managed to pull it off, the exhaust system is out of the boat.  Took about three hours, not so bad.  Now we'll see if I can get it all back together.

Cheers,
Rob W,

IMG_1391(1).JPG

IMG_1416(1).JPG

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iProducts do that a lot...but we can see the pictures..I just flip my monitor over and I am good to go! :)

I am sorry that those diesels make such a mess of the engine box. The boat was never designed for a big ugly diesel.

One thing I did when I replaced my exhaust hose was to NOT have it come up the hole into the galley, but stay under the seat all the way out to the hull..but my Vetus muffler allowed for that a little better because the outlet was angled that way..newer hose will also be (slightly) more flexible. Typically exhaust hose falls apart from the inside out..the inside layer fails, exposes the metal wire, which rusts, and the exterior layer is the last to fail while it still looks great. So, I would recommend you examine it very closely while you have it apart. You're 90% of the way there now,..the last bitch will be getting the new hose past the ice box..The next junction of the exhaust hose will be in the "sail locker" on the port side, roughly under the port cockpit winch. The flappers like to fail in those junctions too. I put a 45° Centek elbow in its place and got rid of the big bronze flapper valve..the pin fails and the flapper sits cockeyed in the housing.

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