Willard 730 Diesel Repower Project

[jyasaki]

What are we looking at in the last 2 pics? The area for the fuel tank, or part of the tank itself in place?

Seems to me that you have a part of the bilge that won't drain at all (the opening in the 2 pics.) Unless you're planning on filling the space completely with something non-absorbing?

Or am I missing something?

jky

[Bigtalljv]

you're missing something. (sorry forgot the smiley) They glassed in a tunnel for the bilge to drain through. They are using the existing walls of the boat as the tank walls. They are going to fill that space with diesel.

jason

[ncp]

Originally Posted by clloyd

Exhaust is now simpler. Instead of using both outlets, old one is sealed and new one is a straight shot out the back.

Looking good, as expected!

1. What is the purpose of the half moon shaped piece welded into the exhaust pipe?

2. Will the top of the tank be level with the pass-thru openings to the engine compartment? (so that the opening can be utilized)

3. All glass to cover the circular holes or glass over ply?

[clloyd]

1. Tony called it a sprayer. I'm assuming it flicks the water up into the exhaust stream? Maybe makes it even cooler on exit? Not sure.

2. Yes. So all tank fitting will be on top. Fill will be under deck so to remove the old tripping hazard, yay!

3. I believe they used glass over foam which is the same as original layup.

[jyasaki]

Originally Posted by Bigtalljv

you're missing something. (sorry forgot the smiley) They glassed in a tunnel for the bilge to drain through. They are using the existing walls of the boat as the tank walls. They are going to fill that space with diesel.

jason

Well, that makes a bit more sense. I had assumed a finished tank would be dropped in, but apparently (now, anyway) not.

Thanks, JV;

jky

[clloyd]

Tank progress.

They just put in the first white coat of special resin that is made for fuel and chemical tanks. Needs two more coats and then a final coat with wax in it.

You can see there is a solid glass baffle as well as solid glass ledge all around including on top of baffle. This is what the lid will be glassed too. The lid will be angled down which maximizes tank capacity in front and allows a fill tube and senders installed aft top side. Deck will have access plate to get to fill.

Lid will be divinicell and glass which fulfills my wish of having no wood in this thing.

Will be glad to be done with glassing since it's slowing everything else down.

tank should be pretty sweet when done though.

[clloyd]

Old tank chopped to reuse the old deck plate.

Eventually I might glass up a real nice light deck plate but this is a quick and practical solution as first done in the "other" Willard build thread.

[Bigtalljv]

It's a bad year for diesel tanks....

And mine's a Zodiac thank you very much

Jason

[clloyd]

To quote Steve Martin, "Well excuuuuuuse me!" lol

So we are going to put a big square plastic hatch into the deck plate and cut out the old access hole and fill hole. The plate wasn't as heavy as I thought so I doubt I'll change it unless it starts becoming an aluminum painting nightmare.

I'll actually have some storage under there for some small things.

[clloyd]

More tank progress. Yes, this is a long process but very close now.

The gray and white surface is the inside of the tank cover. The gray is the part which will be bonded down to the flanges inside the tank. The top of the lid is still raw foam since it will be glassed in place after it is bonded down.

You can see the bent fuel pickup tube and the return which does not have a tube (per what QSB requires). The short fill which will have a sealed cap and the vent tube.

The fuel sender hole will be the last one to be installed.

[clloyd]

Yay! Getting out of the glassing shed today and boat is getting washed off and ready for dry fit of engine and tranny.

Tank is basically done. Last gel coat applied to top. Gelcoat is still wet in pic. Sender needs to be mounted still.

Top drains very cleanly into bilge if needed from condensation or whatever.

[clloyd]

Pulled the Konrad 520 leg and getting ready for the 560 to go on.

Also, finishing up the fuel tank and deck plate.

Here's some shots of the deck plate (former top of fuel tank) being dry fitted back.

We added a bomar hatch to access the new fuel fill below deck.

[clloyd]

Shots of BAM tranny attached to engine, ready for dry fit today.

Had to rewire my 24 volt ignition key and accessory circuit to 12 volt, so we can run the electronic control module on the engine off 12v. Luckily my guages can run either 12 or 24 volt.

[clloyd]

Waited a long time to see this.

Engine dry fit in boat.

I would say that is a tight fit.

[ncp]

True, tight - But certain things actually look more accessible that on the 6BT - filters and water pump come to mind!

[clloyd]

Yeah for sure.

Actually, water pump, filters and even the belts look like easier access.

[clloyd]

Custom exhaust dry riser and wet shower downhill mocked up.

Old 6BT exhaust came straight out and down off turbo and was marginal for safe distance above waterline. My old engine had definitely gulped some salt water through the turbo somehow.

This exhaust gives us tons of margin. Won't be worrying anymore about it.

[clloyd]

More progress.

Shown in photo with yellow elastomer teeth is the fancy coupler between the Cummins and tranny. Engineered to take a lot of torque and supposedly a 0 service item once installed.

Rough aligning of drive shaft using laser and shaft alignments jigs.

Jack shaft has u-joints so alignment not super critical but still useful for getting in ideal position.

New Spicer 1350 drive shaft and u-joints. Old shaft went for service and was completely rusted together and unserviceable. More money, but not too bad.

[clloyd]

New Engine has been sitting in a warehouse for 7 years.

Starts for the first time with one crank. I've been waiting to hear that sound for a long time now.

At this point in the project, I'm pretty much at the end of my rope, both financially and time wise. I need it to be done.

Luckily engine is ready to be dropped in. Engine harness is made and everything is ready to be plugged in. Just finishing the fuel connections to tank.

First run of New Cummins QSB 330 going into Willard Rib - YouTube

Throttle up. She's a lot quieter and clean than the old 6BT that's for sure.

First run of New Cummins QSB 330 going into Willard Rib - YouTube

[ncp]

That is a beautiful sound!!!