Broken Flange at Exhaust Mixing Elbow - Yanmar 2GMF

[pham]

Replacing the mixing elbow on my Yanmar 2GMF, all 4 bolts came out easy. Unfortunately, the 4th only came easy because it took a piece of the flange on the heat exchanger with it.

The way I see it, I have four options:

1) Replace the heat exchanger. These things are pricey. Don't love the idea of spending another $2400 on parts, especially since removing this will likely break something else.

2) Find somebody to repair it - not sure this is possible as the piece seems to have vanished. So there's nothing for them to reattach. Is repair an option in this scenario?

3) Use some JB weld epoxy to glob on it, let it set up, then drill and tap a hole - they advertise their 'SteelStik" to be able to do this. This feels like a lot of work for a repair that's bound to fail.

4) Lose the gasket that came with the new 3-part elbow assembly and glob on some high temp RTV or their muffler and tailpipe sealer, and put it back together with 3 bolts.

I just want to go sailing! But I haven't been able to get the boat out of the marina because of this engine. Anyone have any insights or dealt with this before? I'm tempted to just do number 4 and see if it works...worst case I take it back off again and replace the heat exchanger.

Thanks.

 

[Jim Legere]

A welder might be able to braze a nut on the back of the flange where it broke. Might even be possible to repair in-situ but I can't tell from the photo provided. Best would be to get the manifold off the block and to a good machine shop.

 

[duality]

heres an old post of mine, reach out to them!

Got to give a shout out to HDI Marine, especially Hailey!
thursday before labor day i was fueling the boat for a lake michigan crossing the next day friday, i noticed that the mixing elbow was leaking. i had remembered that HDI offered a stainless steel replacement for the yanmar. Hailey call me back quickly and asked if i took it apart yet. which i hadnt, she recommended that i also ordered the 90 degree piece that went to the engine. she stated most get broken in disassembly. i ordered both pieces overnight. received friday morning, installed in under 2 hours and week end went on as planned. oh, with overnight shipping ($70) the total was only around $300. sweet deal!
thanks Hailey!

 

[pham]

A welder might be able to braze a nut on the back of the flange where it broke. Might even be possible to repair in-situ but I can't tell from the photo provided. Best would be to get the manifold off the block and to a good machine shop.

Thanks. It's going to a shop today to see what they can do with it. Brazing a nut on the back seems like a good solution. I'll suggest it if they don't come up with it first.

heres an old post of mine, reach out to them!

Got to give a shout out to HDI Marine, especially Hailey!
thursday before labor day i was fueling the boat for a lake michigan crossing the next day friday, i noticed that the mixing elbow was leaking. i had remembered that HDI offered a stainless steel replacement for the yanmar. Hailey call me back quickly and asked if i took it apart yet. which i hadnt, she recommended that i also ordered the 90 degree piece that went to the engine. she stated most get broken in disassembly. i ordered both pieces overnight. received friday morning, installed in under 2 hours and week end went on as planned. oh, with overnight shipping ($70) the total was only around $300. sweet deal!
thanks Hailey!

Yep - I got both halves from HDI. Glad I did, because the threaded portion of the lower part is in really bad shape, and the dual threaded connector fell apart completely. The issue here isn't with the second half of the elbow, though - the flange on the heat exchanger where the base of the elbow connects to the exhaust manifold fractured.