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Author Topic:   Transom Brass Thru-Hull replacement procudure documented
Jeff posted 03-16-2013 10:24 PM ET (US)   Profile for Jeff   Send Email to Jeff  
Since Derf's old thread (linked below) is missing it's images I thought I would document and repost this procedure.

Please reference this thread for some great information from Tow W Clark on part sourcing as well as some other good bits of info.

This procedure was performed today on my Grady-White 190 Tournament but, the process is the same for a Whaler.

First step is to remove the old tube. I use a large flat bladed screw driver and a hammer to work the flared end of the tube in toward the center. Once it is worked in, you need to them hammer it out the other side. This can be a process if you have a really bedding in tube. DSC_1774_zps56a006d1.jpg?t=1363477779 DSC_1775_zps9ebdc084.jpg?t=1363477797 DSC_1776_zpsfbfbe65d.jpg?t=1363477793 DSC_1778_zps1ccc7d17.jpg?t=1363477805 DSC_1809_zps9476a567.jpg?t=1363478035

Now that the out tube is knocked out, check the wood core. Mine was dry and rock solid. Relieved! DSC_1780_zpsd59f0d2f.jpg?t=1363477818

Next step is get the first flared end. I measured and cut (with a tubing cutter) a rough length. Now to flare. To get the brass tube to flare and flare without splitting, you have to anneal brass. I use a plumbers torch and get the tube GLOWING red hot and quence it in water. DSC_1784_zpsaaea849d.jpg?t=1363477838 DSC_1785_zpsf3fefac9.jpg?t=1363477858 DSC_1786_zpsefd8284c.jpg?t=1363477864
Once quenced you, use the flaring tool set up with one of the die's facing in and the other flipped over to the flat side. This works force the die into the other end to start the flare on the other end. DSC_1791_zpsbfe32c53.jpg?t=1363477880
Tighten it down and keep going until the one end is FULLY flared. DSC_1792_zps196f7582.jpg?t=1363477898

Now that you have a flared end, put an o-ring on the flared end and dry if the tube into the transom. DSC_1794_zps11a54e96.jpg?t=1363477916
Once in, install 2 O-rings on the other end. This will give you the exact length you need to accept a flare on the other end. Mark the tube DSC_1798_zps6ef9053e.jpg?t=1363477950
Cut the tube with your tubing cutter. DSC_1799_zps9aa7712e.jpg?t=1363477953
Now anneal the other end to flare it (repeat the process above).

Installing the new tube.
I like to coat the entire wood core with 3m 4200 prior to putting the new tube in. You really do not need to do this but, I like it because it seals the wood and will keep it from ever getting wet, ever if there is a failure. The only problem is, if you have to take the tube out later down the road, it takes a lot more hammering to get it out. DSC_1800_zps00533a38.jpg?t=1363477964
Now I put a bead of 4200 along the flare and install an o-ring. DSC_1802_zpsd3cdb807.jpg?t=1363477978
Now, force the tube back into the hole. To get it all the way in you may have to put a die from the flaring tool into the end and hammer it through. Once close to all the way through, I install another bead of 4200 in front o-ring to provide a perfect seal against the gelcoat. DSC_1803_zps88e92095.jpg?t=1363477989
Now on the other end, install a bead of 4200 around the tube and the gelcoat. Install an o-ring and put another light bead around the front of the o-ring. Install the die on the inside, run the bolt through, put the nut on the other side to secure both dies in place. Now, start turning your wrenches. The inside will start to flare. Keep going until you get a complete flare and plenty of squeeze out of 4200 to ensure a water tight seal. DSC_1804_zps6115cd26.jpg?t=1363477990 DSC_1805_zps89c65f98.jpg?t=1363478005
Besure not to over-tighten. If you do, you will force the o-ring out.

Remove the bolt and dies and clean the squeeze out of 4200 up with acetone. You are now done and should have a sealed tube. DSC_1807_zps5f8ca286.jpg?t=1363478022 DSC_1811_zpse36aaf91.jpg?t=1363478051

Hope this helps..


PS. Jim if you would like these images to permanently embed let me know. I would be glad to share them.

sraab928 posted 03-17-2013 07:16 AM ET (US)     Profile for sraab928  Send Email to sraab928     
Nice writeup Jeff - Thanks for taking the time - I have done this a few times now. I am getting ready to do it again on my new 19 and the refresher course was welcome.
Mambo Minnow posted 03-17-2013 07:26 AM ET (US)     Profile for Mambo Minnow  Send Email to Mambo Minnow     
I like the location of your Racor fuel filter in the transom well. This is my spring project now that I can not get ethanol free fuel.

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