Welcome Forums Mechanical Systems & Maintenance Engines 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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