Building our Genset Water Pipes & Exhaust Stack!

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Building our Genset Water Pipes & Exhaust Stack! - Project Brupeg Ep.364

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Күн бұрын

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With Damon the Electrician booked in for two days time we had to make sure that the new genset was ready to run so we can program in into the new DC electrical system.
That means the water cooling pipes needed to be finished and the exhaust and muffler needs to be functional. Of course when the brand new silicon pipes that should have worked, didn’t, we absolutely did not over-react and weld the most over engineered solution to a leaking hose clamp so they were water tight…
And we stopped muffler juice from entering our fo’shizzle.
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Пікірлер: 119

@FlyingConey Ай бұрын

Just a quick information, keel cooling pipes need to have valves on the inside of the hull. Sometimes the pipes develop a leak over time and since it's still a closed system it might take some time until it gets noticed. But in the mean time every connection of the cooling system becomes absolutely safety relevant. If one fails it's likely that the vessel will go down. We always close our sea valves from the keel cooling when we're not underway. All the best!

@ProjectBrupeg Ай бұрын

Hi guys. Brupeg was never designed with valves in the cooling pipes and lasted fifty years. That said valves are a key item that does need to be fitted. Now that we have bolt on flanges it’s easy enough to add them and something we will do. Love your boat, she’s very pretty and it’s great watching your videos.

@rolandtb3 Ай бұрын

Leak free with options to improve if needed. Roof exhaust needs some finishing touches as mentioned.

@lancer525 Ай бұрын

Absolutely agree with the valves on the coolant pipes inside the hull. We had a vessel sink at our marina when their keel cooling system sprang a leak, and by the time anyone could get to it, the vessel was already too far gone. Valves shut off when you're not using them. Safety first!

@ProjectBrupeg Ай бұрын

Now that we have a bolt on flange valves are a possibility. Something we can add as an upgrade. Previously the boat never had them so it wasn’t something we added. That said, it’s an easy addition.

@lancer525 Ай бұрын

@@ProjectBrupeg The way you engineered it, it absolutely is an easy thing to add. Better to have it and not need it, than to be out at sea, hundreds of kilometers from anything, and something catastrophic happen.

@BobDavis-n2w Ай бұрын

I was never any good at soldering until I learned to braze. I learned to braze in welding class as a step into stick welding because it is easier than stick and it teaches heat management. Learning brazing and welding then improved my soldering... and yes, flux is imperative in both brazing and soldering. The key thing to remember both in brazing and soldering is you are not trying to melt the base metal. You are only heating the base metal. Once it starts getting up close to temperature, start dipping the rod into the heat cone and rub it into the metal. When the temperature is right, the braze rod will melt and flow off the heat from the metal. Soldering is similar to brazing but don't use direct flame on the solder. Hold it near the heat to pre heat it and rub it on the metal to melt it.

@TheGnomestead Ай бұрын

Tip from a tradesmen. Use a wet rag to wipe your joints right after and they will smooth out. It also cleans the Flux off the pipe which can cause corrosion over time if not cleaned off

@bobuncle8704 Ай бұрын

Really like how you interlocked those flanges. Trick work.

@ProjectBrupeg Ай бұрын

Thanks

@brantyancey7028 Ай бұрын

That pipe work was sheer genius!

@bartjohnson8139 Ай бұрын

Man, I sure wish I was there with you guys to share in your adventure! The design, fabrication, then settling back and saying, “that sure was a lot of work, but just look at the results!! (long pause) W T F was I thinking!?!?” But then the fun starts all over again! Anyone that actually get out there and does things, instead of just sitting back and armchair critiquing someone else’s hard work, knows the joy I speak of. Good on you guys for DOING! Like I said, I sure wish I was there with y’all!! Like having your own candy store; but there’s always that one sticking gum ball machine that can be made just a wee bit better! Cheers from Dallas!

@BillyBob38846 Ай бұрын

Well another great video and some masterful work that looks really nice finished. One step closer to seting off on her first long voyage. See yall next week! 👍

@ChrisHarding-lk3jj Ай бұрын

I am surprised you didn't get a stainless steel muffler. V band flanges work really well for exhaust and I use them on almost all of my builds. To save time you can easily buy a stainless steel muffler for the main engine, just get one for a semi truck.

@ProjectBrupeg Ай бұрын

It’s a cost and access issue. Yes we can buy a stainless muffler for the main or genset but in Aussie it is disproportionately expensive. We have designs and plan to build our own stainless muffler for the main engine and for the genset. For not the cheap mild steel muffler while being a poor long term solution will get us independent of the dock and allow us to reduce overall costs to the project so we can do more for the projects we want to support.

@DM-tn6jd Ай бұрын

Dude the complexity of what you and Jess are doing astounds me weekly. I’m 500% sure you are over engineering it, but I’d do the same and it’s great watching. As a Kiwi you’re still annoying, but you’re OK… Cheers from Edinburgh ☮️

@kiwi_welltraveled4375 Ай бұрын

Another master class in positive logical thinking. Have problem with original idea.......manufacture an upgraded permanent solution! Slowly but surely the goal gets closer and closer 🙋🏻‍♂️☮️❤️

@nigeltoleman6308 Ай бұрын

You got there in the end. Would it have been simpler to drop a sleeve over the keel cooling pipe and weld around the end? This would have allowed you to use the original silicone hoses.😊

@robertmalis4493 Ай бұрын

Love the content guys I love how transparent you are with everything

@ProjectBrupeg Ай бұрын

Thanks Robert

@robertmalis4493 Ай бұрын

@@ProjectBrupeg if you guys ever make it to Florida with the boat? You guys have a place to stay on land if you like

@ProjectBrupeg Ай бұрын

Thanks Mate

@robtorresan6463 Ай бұрын

Hey Dames, if that rotator is designed for welding, and I assume it is, then the earth strap will be built into it, an internal item, there should be a position on the machine for the earth clamp. Awesome bits of kit aren’t they? Absolute game changer.

@ProjectBrupeg Ай бұрын

It’s an incredible bit of kit. there is a tag but it’s not marked as an earth point and it’s fairly small so I wasn’t convinced it was a good idea to clamp onto it. I need to pull the covers so I can eyeball that structure to make sure I’m not running full amps via a 4mm bolt or something silly

@ProjectBrupeg Ай бұрын

@justinepaula-robilliard yeah I just need to pick the covers off and get my head around the earth path. Assuming it has absolutely zero earth ability from factory it should be pretty easy to fabricate something spring loaded up

@shaneedmonds84 Ай бұрын

Don't trust old life rafts! The glue that holds the seams together often dries and perishes. But great for a fun episode.

@waynerudiger1756 Ай бұрын

Classic Brupeg engineering love it!

@ProjectBrupeg Ай бұрын

Thanks Wayne, definitely was a measured over reaction to a leaking hose clip

@twoeagledrones Ай бұрын

Looks good on the brazing. When I saw you hit it without the flux, I said uh oh, but then you figured it out pretty quickly. I use MG and silver solder for musical instrument repair.

@AM-ni3sz Ай бұрын

Nice problem solving.

@ProjectBrupeg Ай бұрын

Thanks

@bartjohnson8139 Ай бұрын

I’m wondering about the long straight through the roof exhaust run terminating at the short bends at the vibration mounted muffler. The muffler now has some wiggle, that will be exacerbated by the long up pipe. Even though you plan on installing a stainless muffler, I suspect that this may always be a point of failure. I was thinking that by the time the exhaust gasses have reached that point, a high temp silicon joint located right below the joints would provide a little more vibration protection.

@dcallan812 Ай бұрын

Only one way to see if the heats going to melt the mounts. Fire it up and see if they get toasty great update 2x👍

@Finn-McCool Ай бұрын

The entirety of the cabins below would be Hobbiton. Cabin 1 would be Bag End and Brupeg Westfarthing, then the waterways the Shire and onward to Lindon Mordor and beyond!

@mattpalmer5890 Ай бұрын

MarineSafe Slacks Creek Brisbane are RFD Life raft Service Agents. These days Service Agents stick to their own preferred brands as it costs so much to have technicians accredited for every brand of life raft. The real cost will be replacement of your EPIRB (if it's equipped with one) and the supplies. We use heaps of them every year for training purposes and most get packed, and repacked continually for years without issues. Might be a good idea to ensure that life raft complies with your survey as well - sure you've thought of all that though - Thanks for the vids !

@ProjectBrupeg Ай бұрын

Thanks Matt. Yeah the plan is to get it replaced and any repairs done very soon

@propylaeen Ай бұрын

The master of space fight did it again. The Bruce Lee of cramped spaces go get a pair of yellow black Asics Tiger you deserved them.

@williamhamill813 Ай бұрын

Careful with that silicon tubing. I have seen that stuff split and sink a boat that had it on an intake for a washdown pump. That application should be ok because the generator is protected.

@SuperDriver379 Ай бұрын

The muffler having the lip around the top in my experience really shortens the life of the case with the environment that it’ll live in, you may get a year out of it, but the rain and salt water cup on the top of it will likely be it’s failure point. The only solution I’d know to really eliminate that would be changing it’s orientation 90° that wouldn’t really be possible in this application, or maybe welding a stainless cover of sorts to the pipe out the center and the circumference of the muffler case, but often the rolled edge mufflers like that are very thin. Do what you wish with this information. When you build your stainless muffler you could have them share a case as one “unit” but with separate compartments for each engine. A simple reverse flow section for each engine would make it the quietest with the lowest effort, I’ve built a few of them myself for excavators and bulldozers that work in forestry applications where they require 3/8” case and stack to be able to survive limb strikes, that would be overkill here but the reverse flow design is pretty maintenance free and doesn’t degrade like packing does.

@ProjectBrupeg Ай бұрын

Thanks, yeah it’s the wrong muffler for a boat but it’s a proof of concept to figure out if it is quite enough etc. we have some 10” schedule 10 pipe that I plan to split up and build a decent stainless muffler for the main and the genset. Now I know this tin muffler is good enough from a sound point of view I’ll just roughly copy in stainless. I’ve never built mufflers before so I’ll do some reading and watching on design etc before tackling that build

@birdfeeding Ай бұрын

That was a great solution!

@MrBiddo 22 күн бұрын

future reference heat the inside of the joint.

@RobJohn80 Ай бұрын

Most welding positioners have a spot to connect the ground somewhere on the base of the unit so you don't have to attach the ground to the part. Instead of using flanges on the keel cooling lines I would have used -32 stainless steel male jic weld on fittings. Metal on metal 37 degree flare fittings are extremely reliable.

@ProjectBrupeg Ай бұрын

I think there is a tag but it’s not marked as an earth point and it’s fairly small so I wasn’t convinced it was a good idea to clamp onto it. I need to pull the covers so I can eyeball that structure to make sure I’m not running full amps via a 4mm bolt or something silly

@johncatt1867 Ай бұрын

I am curious if you could have used the tig torch to braze the cap instead of the map gas and flux?

@aaronp1434 Ай бұрын

Why not weld the notched flanges together to make one “figure 8” flange, that could make the gasket easier to get to seal?

@bishopkinlyside8477 Ай бұрын

Hi guys, for your first try at braising doing okay and the only thing I would say and it’s only my suggestion you probably know more about it than me. I always used to bend the rod over so if you go to Pope yourself in the eye it’s not a sharp end it’s around and it hurts a lot less.

@president2 Ай бұрын

Love it so much keep it up as always 💘

@tas32engineering Ай бұрын

You can always refer to a computer that is what I like about the modern world. Bulkheads & valves are designed to stop a water breach. Always have some round wooden bungs avalable for such a issue its a cheap minor repair. A few laminated books to help new crew to follow procedure like emergencies, marine radio, engine room maintainance, diving procedures should all help with explaining detail to new people. You have a copy on computer if its missplaced. A laminator & binder should cover your need & save on explaining why things havecto be done a certain way. Besides forgeting about the fux. Its your boat enjoy.

@tas32engineering Ай бұрын

Operating a mill cutter on a grinder at INCAT. Makes for being cautious in confined spaces. Just takes a few seconds.

@kellythomson3057 Ай бұрын

Stirlings performance steel has short radius shed 40 bends in stainless. In various sizes.

@ProjectBrupeg Ай бұрын

Thanks, did not even know they existed. will check them out. Dame

@1425race Ай бұрын

Was looking forward to seeing the gen set fired up in this vid. I was robbed.

@ProjectBrupeg Ай бұрын

So close but ran out of time. Next episode, just gotta finish a few welds. Spent the week buried in the battery room wiring like crazy with Damon

@1425race Ай бұрын

@@ProjectBrupeg No sweat mate was only joking fully understand the efforts you and Jess put in to these vids.

@alasdairhamilton1574 Ай бұрын

Jess, Hobbiton is the village, so your room (hobbit hole) should be Bag End! 😉. Beautiful place Hobbiton I was there in February this year, spent a month on the North Island☀️☀️☀️☀️, sure beats North East Scotland in the middle of winter 💨❄️🥶.👍🏴󠁧󠁢󠁳󠁣󠁴󠁿

@ProjectBrupeg Ай бұрын

We like the idea of Hobbiton being our personal shire

@alasdairhamilton1574 Ай бұрын

@@ProjectBrupeg No Admittance except on party business 🧙🏻‍♂️🧙🏻

@mikeskelly2356 Ай бұрын

Every 'inventor' works by 'Trial and Error'. For every handy solution to a problem, there are several prototypes that wound up as paperweights and 'spare Parts'. You're not 'Rebuilding', you're Creating anew, so don't feel like you don't rank among all those other 'rank' inventors! There's probably steel trawler owners scribbling notes for every fix you come up with.. 🤙🍺

@ProjectBrupeg Ай бұрын

Thanks Mike. Sometimes it feels like we are dragged over the coals for trying stuff. Your words are really timely and appreciated. Dame

@mikeskelly2356 Ай бұрын

@@ProjectBrupeg Brupeg has come from the 'Back of Bourke' to a right corker, you guys rule! 😘 Hope that's not too 'Sydney'

@tonyelkan5348 Ай бұрын

I ran into a similar problem with soldering a while back. Don’t know why, but the solder would not stick as long as the flame was on the piece. If I moved the flame away and THEN touched the solder to the piece, the solder flowed & coated beautifully

@ProjectBrupeg Ай бұрын

Huh, the more you know! That’s really interesting. Thanks for that

@Youtuber-k2p Ай бұрын

It was said above but with brazing and soldering you melt the stick by touching the base metal not with the flame. This guarantees the temp is correct for the solder to flow.

@stephenreese5921 Ай бұрын

They have flux core wire fore a tig welder. The flux fills the center (core) of the wire!

@andrewhill7595 Ай бұрын

Maybe change the name to "Murphy's Law" just a thought.

@stephenreese5921 Ай бұрын

The rotating “carousel” is akin to the one used by Rocket Lab or SppaceX for welding their boosters.

@ProjectBrupeg Ай бұрын

Identical. Just slightly smaller…

@garyphillips7993 Ай бұрын

Probably just an illusion, but that muffler/bracket looked like it would have fitted behind the main stack - in front of the solar panel - over the hole if the pipe came straight out of the bottom where the drain hole was without being too close to the solar panel? Definately not overengineered 😉👍

@davidharding3058 Ай бұрын

Ooops I also forgot to say if your welding 316 stainless steel, you can use this across most connections 316 down to mild steel as this is what you would be using, 316 on a boat 304,309,? I would never use a lower grade if I was using 316 all the time on a boat . As I think 10 years of work becomes a life time of welding. then re welding do it once , Do it the right. We have a saying now because of utube and Google everyone can now be Google tube engineers.😅 🥂🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿😁

@rexmyers991 Ай бұрын

I, too, am worried there is no way to stop sea water from coming in if there is a fracture or break in the system after an unrealized break in the external pipes.

@ProjectBrupeg Ай бұрын

The boat was designed this way and lasted fifty years. BUT, that doesn’t mean it’s a good idea to not have valves. Now we have bolt of flanges it’s easy enough to add them now

@terrywilson1226 Ай бұрын

easy flow heat the job then add flux it Will go liquid then the rod

@MrStrangegoo Ай бұрын

Dame. I think you may have forgotten the sea cocks on the keel cooling pipes in your rush to get the genset up and running. You have them on the main engine.

@ProjectBrupeg Ай бұрын

Because our keel cooling is a closed loop, it never had any ball valves. Both main and genset were like this for 50 years. That all said, now we have bolt on flanges for the genset we are able to add in ball valves fairly easily.

@larrypardi9143 Ай бұрын

I noticed the hatch closed while welding. Is there another opening so fresh air can enter the space? Worried about welding gas filling the space.

@ProjectBrupeg Ай бұрын

Yeah we have the four main engine room vents. Can’t really be seen on camera but they sit on each side of the engine room

@johnjohn-ed9qt Ай бұрын

The braze for the coolant cap fitting, to the resolution on the video, looks ok. Always look like shit until cleaned up. As a general rule: If you use a torch to braze it, you need flux. Copper to copper (pure) being the main exception, when using the correct braze material (SilPhos, or modern replacement). The appropriate flux is either white (lower temp) or black (higher temp), but if you can use a propane or MAPP torch, white is probably appropriate. You need Oxy-Acet, or Oxy-MAPP to reach the temp where you need the black flux, in general. I keep Everdur (Sil bronze) filler on hand in 1.6 and 2.4mm, not because I use it a lot, but because when I need it, I need it. I am rather envious of the weld lathe. It has no earth strap internally? You can set it up with copper grouns braid and a spring, or a couple large copper-carbon motor brushes. The brushes might be free, as pull-outs from a motor shop.

@ProjectBrupeg Ай бұрын

@N5XHIworkshop Ай бұрын

I sold thousandth of through virbo insulators to Cummins in Texas to mount radiator to the truck body.

@davidharding3058 Ай бұрын

Hi Damien As a welder it's not common knowledge as most joints you have welded are thick to thick if you are welding 0.8 / 0.6 mm your preference would be on the thick side of the metal and just fuse the thinner metal and then use your filler wire with the tig. To silver soldier if your not comfortable in doing this why have you . Tig on low amp's and slow. I would never waste my time in soldering if I had a tig set with pulse i would never have wasted time or money. . And this is something that you have become Efficient in . Happy pulse practice. 🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿🍻

@ProjectBrupeg Ай бұрын

Hi David. We can do pulse but I found the difference in thickness was a nightmare. 1.2mm is thin for me, I’m used to 6mm and the like. So trying to weld the 0.6 felt like tissue paper. I was spending about 90% of my time on the 1.2 and just touching the .6 to get them fusing with some 1.6 filler when needed but that result was a pigsty. Yes it will hold, but I had zero faith it would be water tight. I blew through the .6 a couple of times and filled it up but really had no faith in it. The silver solder was more about making sure it didn’t leak

@Mr19chuck49 Ай бұрын

😊😊😊

@lanerothsailing2293 Ай бұрын

STOP having Fun ! LOL from the shores of Lake Erie USA

@paulstephens5229 Ай бұрын

Could you not have had the muffler in the engine room and just the pipe going up.

@ProjectBrupeg Ай бұрын

The exhaust guys we work with recommended to keep the muffler as far away from the engine as possible. Other wise the heat of the muffler says in the engine room and you have 4-5m of pipe after the muffler that acts a bit like a trumpet and makes the noise awful again. As it is the genset is pretty quiet outside so while the muffler won’t last (because it’s cheap, thin mild steel) the design has been proven and can be improved with a stainless muffler later on

@stephenreese5921 Ай бұрын

The best part is no part! Why not pipe into the engine exhaust stack to vent the generator set?

@ProjectBrupeg Ай бұрын

It’s a few things. Generally it’s best practice not to mix two different engine exhausts. If you get a problem in one it can cross pollinate into the other engine. Back pressure can become a thing for the not running motor. For the sake of a few extra meters of pipe and the complete elimination of possible risk of these things it’s generally better to keep them separated

@stephenreese5921 Ай бұрын

@@ProjectBrupeg Excellent points. I didn’t consider back pressure affecting the non-running generator engine GenSet).

@vincelosurdo9674 Ай бұрын

If underwater cooling pipe springs a leak it will just circulate around engine cooling system,can’t see how it would sink a boat

@ascott6804 Ай бұрын

Could he "T" off the main engine coolant system?

@ProjectBrupeg Ай бұрын

Not really. Opposite side of the engine room but also not best practice to combine two engines into a single cooling system as problems in one engine can affect the other if things go wrong

@glennjaggard7065 Ай бұрын

Hey Dame how come you can't weld the Gen exhaust pipe to the main pipe then you don't need that small one or is it to do with back pressure

@ProjectBrupeg Ай бұрын

@fierohoho Ай бұрын

Why couldn't you just run the geneset exhaust into the diesel exhaust stack?

@ProjectBrupeg Ай бұрын

@fierohoho Ай бұрын

@@ProjectBrupeg Thank you for the explanation.

@waikanaebeach Ай бұрын

You can tig silver solder, it is a brazing process, just lower temperature than braze metal.

@ProjectBrupeg Ай бұрын

I tried with TIG but nearly smoked myself out of the engine room. Figured it wasn’t a TIG option. Didn’t have full at that point either so just assumed I was doing it completely wrong

@kaydog2008 Ай бұрын

Demon I’d still install head and front sails to save on fuel. Just a thought thought. It’s not plossible. Or a simplmle kite sail.

@mwhelan53 Ай бұрын

There are things we know and things we know we don't know and then there are the things we don't know we don't know. They are the bastard ones.

@ProjectBrupeg Ай бұрын

Arnt they just. And you normally only find out you don’t know you don’t know when the consequences turn up! I heard a saying the other day “the dildo of consequence seldom arrives lubricated”. Dame

@Tinker001 Ай бұрын

@@ProjectBrupeg Damnit Dame! You've cost me a keyboard. Also... Beer through the nose sucks.

@ProjectBrupeg Ай бұрын

I feel partly responsible for your predicament

@mwhelan53 Ай бұрын

@@ProjectBrupeg I shall add that pearl of wisdom to my lexicon.

@WaterfrontJustin Ай бұрын

What if you'd just run a bead of weld around the tip of the cooler pipe to make a nipple

@ProjectBrupeg Ай бұрын

That’s possible but it’s a pig of an angle to make a good job of it, with the rust on the outside of that pipe I could t be sure I’d get a solid weld. The top on the other hand could be cleaned up pretty easy

@theessexhunter1305 Ай бұрын

Like the propjet but get it done and gone...Tally Ho has slipped her berth and gone SV Seeker has been gone a while.

@ProjectBrupeg Ай бұрын

We are quite different from both these other projects. Have a look at what we are trying to do on the channel for more context, the unique challenges we face and what happened to the electrical system. Just in case you haven’t done a project of this size with low funds it’s not possible to leave port without a working electrical system with the work we are aiming for and things take time when each job is a big one. We have explained on the channel many times, the boat is not finished and we will be continuing the build for some time yet. It’s just the reality of life that sh*t happens too and we are interested in the truth of this build as much as possible while respecting people’s privacy, not being a TV show pretending everything is great, we don’t feel entitled but rather gratefulness. If it helps and is a problem it’s probably best not to watch. We realise some people expect things to be done perfectly or quickly and appreciate that. But that is NOT us. We love and appreciate that you have checked us out and supported us by watching but we don’t want anyone upset because the reality of our timeline doesn’t work for them. It’s about everyone, it’s about community and nonjudgmental creativity.

@theessexhunter1305 Ай бұрын

@@ProjectBrupeg It is good and you are a good engineer but side projects using beer barrels come on...I have worked on enough (third world ) dive boats to know what works. Good luck but my advice is to stop spinning so many plates on poles as they take up too much time.

@ProjectBrupeg Ай бұрын

We get that, we were trying to work with what we had available at the time and as always if we have the opportunity to work with an expert or volunteer we make the most of it and a new job starts. Even though we would rather focus differently it has got us to here and we are bloody amazed and incredibly grateful. Cheers

@theessexhunter1305 Ай бұрын

@@ProjectBrupeg I will take your advice and un-sub then come back in a few months

@ProjectBrupeg Ай бұрын

Thanks @theesexhunter1305! Look forward to your return. Jess and Dame