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Smoothie – Engine Upgrade

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    • #4155
      CJ
      Keymaster

        I have had a lot of questions about my engine upgrade so I am starting this thread so those interested can follow along, ask questions, and make comments. This process won’t be quick so don’t expect a post everyday.
        Currently I have a Westerbeke 30 installed. I am moving to a Beta 35. See the link. It weighs 370 lbs. and comes standard with a 70 amp alternator. I am upgrading to the 120 amp alternator.

        I will be doing most of the install with the exception of Tom Becker will be helping with the engine alignment.

        https://www.betamarinenc.com/engine/beta-35/

         

        CJ

      • #4157
        CJ
        Keymaster

          Well the 1977 Westerbeke 30 has run for the last time on Smoothie. I’m hoping she will have a new life on another vessel. She has been a good engine and if I was planning on staying in the NW I wouldn’t have replaced her. However, I don’t think traveling to far away places with a 45 year old engine, who’s history I know nothing about, would be wise. For those who do not know, Roxana and I are preparing Smoothie to take us any where in the world. We are considering places north, south, and west. Time will point the way.

          The new engine is on the way and should be here by the end of January. She is a Beta 35. I had to get the red engine because red is Roxana’s favorite color. Happy wife, happy life. Seriously, I have only heard good things about the Beta’s and with our own Ben Thomas being the local factory rep, I couldn’t go wrong.

          The plan is to do this project mostly myself with assistance from Ben and Tom Becker. I am having Tom make the new plates that the motor mounts on. Since this engine sits at a slightly different height/angle than the Westerbeke, these plates will align the engine with the shaft.

          Currently, all the shaft is shored up and the wiring has all been disconnected. All raw water lines are disconnected with just the exhaust left. I hope to disconnect the exhaust lines and the fuel system this weekend with the intent of pulling the motor in a week. I will post pictures of this process as time allows.

          CJ

        • #4168
          CJ
          Keymaster

            The old iron sail has been removed.  I had 5 helpers  (thanks Steve, Scott, Dakota, Ben, & Jeremy) to assist with the removal.  The old engine was a tight fit getting out of the companion way.  However, the removal went well and the weather was perfect and the rain held off until we were complete.  Now for the tank removal and clean up.  I have attached a few pictures for your enjoyment.

            00t0t_45YYWyaWVyt_1200x900.jpg

            Remove.PNG

            IMG_20200126_112406437_HDR.jpg

            IMG_20200126_114354194.jpg

             

            CJ

          • #4566
            CJ
            Keymaster

              The tank is out and cleanup has begun.

              IMG_20200207_132411039.jpg

              Good shot of the shaft shoring.

              IMG_20200207_125557629_HDR.jpg

              Here is a preliminary design for the fuel system.  Before anyone says anything, the manifold shows 6 ports.  That will be adjusted once I know how many I need.

              Fuel Polishing and Filter System 1.jpg

              CJ

            • #4570
              CJ
              Keymaster

                When the original engine was installed the bed logs were shaved only where the motor mounts were to make the engine line up.  This would make it very difficult to measure and align the new engine.  Therefore, we needed to start with everything flat.

                Picture # 1 shows the top of the bed log looking like a hilly highway.
                IMG_20200216_122919723.jpg

                Picture #2 & #3 shows the process of flattening the bed logs in progress.
                IMG_20200216_134545084.jpg

                IMG_20200216_134551189.jpg

              • #4571
                CJ
                Keymaster

                  Picture # 4 thru 6 shows the final results.  Also note, I had to cut and scrape the glass from the sides of the bed logs.  It was separating and holding moisture against the logs.

                  IMG_20200216_135327383.jpg

                  IMG_20200216_135317368.jpg

                  IMG_20200216_122926318.jpg

                  Picture #7 shows 3 broken off lags that I found while planing the bed logs.  These 3 were a b$#@h to get out.  Now I get to epoxy the holes.

                  IMG_20200216_123335927.jpg

                  Next up is moving the battery, charger, and battery disconnect switch to a better place.

                • #4572
                  CJ
                  Keymaster

                    It’s finally arrived.

                    IMG_20200221_063920715.jpg

                    IMG_20200223_191422712_HDR.jpg

                    IMG_20200223_191928085.jpg

                     

                    Dropped it off at Tom Becker’s so he can make the bed supports.  Also, I have decided to go with an aluminum tank that I am having made.  Expensive but forever.

                    Thanks.

                     

                    CJ

                  • #4573
                    CJ
                    Keymaster

                      More progress. Bed logs have been raised to the right height/angle.  Lots of structure has been removed.  Derelict water heater is gone.

                      IMG_20200228_145152894.jpg

                      IMG_20200301_143009377.jpg

                      IMG_20200301_143014671.jpg

                      IMG_20200301_143747909_HDR.jpg

                    • #4574
                      CJ
                      Keymaster

                        Well it’s been a while.  Since my last post I have finished building the box.

                         

                        IMG_20200308_142816026.jpg

                        IMG_20200309_154556091.jpg

                        IMG_20200311_155148311.jpg

                        IMG_20200327_071925450.jpg

                        All she needs now is some sanding and paint.

                        Fuel system is done.

                        IMG_20200316_202647493.jpg

                      • #4575
                        CJ
                        Keymaster

                          Yesterday I had to tap the holes for the clean out plate on the fuel tank.  This piece will be welded to the tank and a top plate will be bolted to it.

                          IMG_20200327_082952446_BURST001.jpg

                          Also, tapping was needed on the bed log plates.

                          IMG_20200327_100154795.jpg

                          How could we forget about the tank.  We realized the metal fabricator put the hole for the sump in the wrong corner.  Tank needs to be re-cut and bent.  The hole should be on the left side.

                          IMG_20200327_131929818.jpg

                          Cutting the baffle for the fill tube.

                          IMG_20200327_132919927.jpg

                          IMG_20200327_154747284.jpg

                          More to come.

                        • #4576
                          CJ
                          Keymaster

                            Now for the sump.  Started with this.

                            IMG_20200327_135508704.jpg

                            IMG_20200327_135943559_BURST001.jpg

                            Ended with this.

                            IMG_20200327_154601753.jpg

                            IMG_20200327_154739081.jpg

                            Made this from a piece of solid aluminum rod.  This is the return fitting and will be welded to the top of the tank. .  Still needs tapping.

                            IMG_20200327_162010932.jpg

                            IMG_20200327_163402712.jpg

                          • #4577
                            CJ
                            Keymaster

                              Last part for the day, the vent line.  This gets welded to the top of the clean out plate.  Made from an aluminum pipe.

                              IMG_20200327_165432946_HDR.jpg

                              IMG_20200327_170531186.jpg

                              It was a productive day.

                              IMG_20200327_172802304.jpg

                              CJ

                            • #4578
                              CJ
                              Keymaster

                                Well it’s been a while since my last update and a lot has changed.

                                IMG_20200404_122532101_HDR.jpg

                                 

                                First up, I sold the old Westerbeke.

                                IMG_20200412_112442940_HDR.jpg

                                Starting to look good.  The enginewell box is almost done.

                                IMG_20200406_155042639_BURST001.jpg

                                Wrapping the bed log plates for the anodizer.

                                IMG_20200415_150254444_HDR.jpg

                                Finally, the box is complete.

                              • #4579
                                CJ
                                Keymaster

                                  The progress on the tank was slow.  I had to have the sheet metal re-bent twice.  Then finished making a few more pieces. Once all the pieces were complete I took it to the welder.  He tacked in the baffles to hold the tank shape.   I then took the tank to the boat and installed it so I could mark the position of the attachment angles.  Then the tank went back to the welder.

                                  IMG_20200406_155321711.jpg

                                  This is the supply tubes for the engine and the heater.  The heater supply is shorter so you never run yourself dry from using the heat.

                                  IMG_20200406_155326584.jpg

                                  This will become the 2″ fill tube.

                                  IMG_20200424_094817759.jpg

                                  Finally we have a tank.  Here we are pressure testing for leaks.

                                  IMG_20200424_095039419.jpg

                                  A shot of the attachment angles.

                                  IMG_20200406_155804221.jpg

                                  Once the testing was complete, as the builder I had to stamp it and certify the tank.

                                  Also if you reply, please reply to all so it hits this forum so others can participate.  Thanks.

                                • #4580
                                  CJ
                                  Keymaster

                                    Next up we had to install the new instrument panel.   This meant we had to cut a big hole in a perfectly smooth cockpit.  Measure 2,3,4 times just to make sure.  It’s hard to get something “level” on a rocking boat.  Patience and persistence pays off.

                                    19348.jpeg

                                    It’s nice to see things going back together instead of the other way around.

                                    19354.jpeg

                                    It was a very tight fit.

                                    19351.jpeg

                                    But with a few cuts to existing structure, Smoothie now has a tank again.

                                  • #4581
                                    CJ
                                    Keymaster

                                      Well, finally the day came for the new engine to be installed.  Three of our sons met us at the boat to make this happen.

                                      19607.jpeg

                                      The crew: the electrician, the Admiral, the helicopter mechanic, the hi-tech wafer engineer, and the ….(I’ve been called a lot of thing).

                                      19601.jpeg

                                      Beta 35.

                                      19600.jpeg

                                      We hand lifted it off the truck onto the cart and wheeled it to the boat.  The dodger had to come off for the installation.  The side of the dodger can be seen in this picture, resting against the front of the walk.

                                      19612.jpeg

                                      The lift.

                                      19597.jpeg

                                      It was a tight fit and we had to turn the engine on it’s side to get it in place.  But Smoothie now has an engine, never to be moved again. Or so I thought.

                                      Also if you reply, please reply to all so it hits this forum so others can participate.  Thanks.

                                       

                                      CJ

                                    • #4586
                                      CJ
                                      Keymaster

                                        The day to align the engine was here.  We thought we would be done in an hour and a half.  Boy were we wrong.  We started at 10 AM and finished at 7:30 PM.  I met Tom Becker at the boat and we started the process.  During the alignment we noticed that the fore motor mounts were hitting the engine brackets.  I’m not sure if the manufacturer recently changed their brackets/mounts but this certainly wasn’t going to work.  This defect meant we had to lift the engine again to remove the brackets and mounts, grind the brackets so there is proper clearance and then reinstall them.

                                        IMG_20200508_125040918_HDR.jpg

                                        Here you can see how we modified the bracket.

                                        IMG_20200508_171114654.jpg

                                        Here is the modified bracket installed.

                                        Next we started the alignment process again.  This time we determined the shaft must have not been centered properly on the old engine.  This meant we needed to lower the engine about 3/16″ more.   We could try to shinagal something or do it right.

                                        IMG_20200508_170903007.jpg

                                        Doing it right meant we had to again remove the dodger, hook the hoist to the boom, remove the engine, and shave the bed logs down 3/16″.   And I thought the engine box was done and the engine didn’t ever have to be moved again.  D$%#!!!

                                        IMG_20200508_170844385.jpg

                                        Messy again.

                                        IMG_20200508_184158548.jpg

                                        Third times a charm.  Once we had the bed logs shaved down and the engine re-installed, we again had to start the re-aligning process.  I am so happy I had Tom help with the alignment.  I would have fought this for a month.  His experience certainly came in handy and now I know it is right and got an education on engine alignment too.

                                        Next up is to hook up all the fuel lines, battery cables, intake water, exhaust system, wiring harness, etc.  Once all this is done we can start Smoothie and take here out of the slip.  The build out of the engine room/compartment will come after that.

                                        Smoothie now has an engine installed, anchored down, and properly aligned.  Thank God.

                                         

                                        CJ

                                      • #4587
                                        CJ
                                        Keymaster

                                          Sea trial and break in completed.  Good news, everything worked as desired with no leaks.  I can finally say the re-power/re-tank project is complete.  I started the engine for the first time on June 12th.  Roxana and I took Smoothie out of her slip for the first time this year on Sunday June 14th.  We ran her up to buoy 18 and back while following the manufacturers procedures.

                                          15 mins at 50% power

                                          15 mins at 75% power

                                          15 mins at 100% power

                                          1345.jpeg

                                          Now starts the build out.  Hope to have the new engine room/companion way done before Lazy Days.

                                           

                                          Also if you reply, please reply to all so it hits this forum so others can participate.  Thanks.

                                           

                                          CJ

                                        • #4588
                                          CJ
                                          Keymaster

                                            Finally complete.

                                             

                                            From this:

                                            00t0t_45YYWyaWVyt_1200x900.jpg

                                            IMG_20200209_115758933.jpg

                                             

                                             

                                            To this:

                                            IMG_20200524_155231519_HDR.jpg

                                             

                                            CJ

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