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Old 03 May 2020, 23:59   #1
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Country: New Zealand
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Boat name: 1979 MKII Zodiac
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80s MKII Zodiac restoration valve issue

I have just purchased a Mark2 Zodiac (mid 80s it think?) for $200NZD which I intend to do a budget restoration on.



The main issue I have encountered so far, is the intercommunication valve being seized. I can't seem to pull them out or turn them.



I tired to turn the I.C valves to free them up with a spanner but in the process Ive damaged the brass thread. And now the Darrin valves won't go in either .



How would I go about removing them firstly? and how would I re thread it?



My other alternative is to cut the I.C valves out and somehow seal the compartments, Then install new valves.



Any thoughts and advice would be much appreciated!
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Old 04 May 2020, 08:04   #2
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Welcome to the forum.

What you have there is a pretty rough but serviceable Zodiac MkII Grand Raid, made of hypalon with their patented inter-communication valves. Damn fine boats. They still make them, but you'd be lucky to change out of £5k, and that's without an engine.

Chances are you need this tool. I take it you just used claw grips? That might have been an expensive mistake, but they might be salvageable. In the meantime, spray some penetrating oil on them such as PlusGas and wipe off any excess.
https://www.rib.net/forum/f50/servic...ves-46297.html

Chas in the link are still there so email them regards the tool and PDF instructions. They are a Zodiac dealer in the UK. If you can save the valve, it will need new rubber cap insert, rubber diaphragm and gasket for a proper leak free seal, and the small issue of threading it again. I think a replacement is base Z2107 and cap Z2108.

I see you have the aluminium floor to the side. Do you have the aluminium stringers too? They often go missing, but you need them to keep the floor rigid once it locks in place.

Anyway post up pictures as you progress. Any loose bits of hypalon, then now is the time to repair. You need 2-part hypalon glue (see Polymarine site) and temperature and humidity are critical, as is preparation.
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Old 04 May 2020, 14:28   #3
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Did you already take the nut/spring out in the center of the valve?
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Old 04 May 2020, 23:43   #4
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Thanks for the help!


I do have the complete floor I pumped it up and installed it last night.

Ive just pick up a Darrin valve I think "Z2107 and cap Z2108" are the equivalent but it fits anyways.

The thread is a bit bugged on one of the valve so I think it may need to be re-threaded. I don't have a tool so I will need to find a solution.

I have a compete valve assemble so the next this is to get hold of a valve tool to free it up.
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Old 04 May 2020, 23:44   #5
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Quote:
Originally Posted by brveagle View Post
Did you already take the nut/spring out in the center of the valve?

Yes is did.
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Old 08 September 2021, 05:28   #6
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Country: USA
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Excellent video on IC Valve repair

I'm in the same situation as a lot of others with the Zodiac Mk IV Grand Raid that I bought. It's a 1977-1978 and the valves are frozen tight. I'll be rebuilding/repairing all of them ASAP. I found this great video showing how it's done.
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