Sailing Blue Pearlvideo
Ep 46 | A major repair we've been putting off
4 June 2023 · 18 min · 2K views · Escondido
What this video covers
A 20kW Westerbeke diesel generator on Blue Pearl requires an emergency repair after a saltwater leak develops in the exhaust manifold end plate.1:05 Corrosion destroys the aluminum mating surface and strips a bolt hole, rendering a standard helicoil repair impossible.6:53 The owner attempts to rebuild the corroded manifold surface using JB Weld epoxy and a gasket maker, but the initial attempt fails, resulting in a larger leak upon startup.11:38 A second repair attempt involves applying a fresh patch of JB Weld, which is cured rapidly using a borrowed heat gun to achieve a hard seal.16:09 While the generator remains inoperable during the 24-hour curing process, the crew relies on a portable Honda 2200i generator provided by a fellow cruiser to maintain refrigeration and battery charging.15:56 The final repair successfully seals the manifold, allowing the generator to run without leaks.17:16 Epoxy and heat-curing can salvage severely corroded aluminum components when replacement parts are unavailable in remote anchorages.
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