Marelon seacock maintenance

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dave_and_dd

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Apr 13, 2015
157
Catalina 309 Port Charlotte
Hey guys - my Catalina 309 (2007) has what appears to be the OEM 93 Forespar seacocks. I'm getting a bit of a drip from the galley sink seacock. Hard to see exactly where it's coming from, but it seems to only drip when open (which is never for very long) and it's not a lot - like 3 drops a minute.

Questions: do you guys lubricate your marelon seacocks regularly? on the forespar site, the installation instructions specifically say lubrication is "generally not necessary". But on the maintenance page it says to lube twice a year (only recently found that).

It does say to cycle them at least every month. (some of mine i'm guilty of not doing this).

Has anyone done a rebuild on these? Is that likely to stop a drip? Looks like I can get a gasket kit which has 2 gaskets and 2 o-rings. (They say you can do this while in the water by plugging the outside, but I'm going to be hauling out in a month or two anyway and will do it then).

Last time I hauled (2 years ago) I did lube all of them and will do that again too.

What's been your experience?

Thanks,
David - in Port Charlotte, FL
 
sail sfbay

sail sfbay

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Feb 21, 2013
4,638
Hunter 46 Point Richmond, CA
Good on you for exercising monthly. Forespar recommends to exercise them quarterly and lubrication is not required.

"FORESPAR® MARELON® Thru-hull/seacocks .................are relatively maintenance free. Generally, lubrication is not required. What is required is to open and close them on a regular basis (4 times a year minimum). The frequency this is required is determined by two (2) things, whether the valves are routinely kept open or closed, and the rate of sea growth (weed and barnacles) in your area. If the rate of fouling is high and the valves are not actuated regularly, this build up of growth can cause any valve to turn hard or not at all. If the valve becomes stiff due to lack of use and sea growth build-up, it must be cleaned. The restriction of flow into the valve may cause harm to the machinery it serves and the valve may seize if not maintained................... All MARELON® integrated valves have a removable plug in the handle (white cap with loop). This plug is made to fit into the external thru-hull (non-screened style only). In an emergency, this plug can be placed in the thru-hull (water pressure will keep it in) and the valve disassembled while the boat is in the water. Someone must get wet, but the boat does not need to be hauled for valve repairs. By tying a lanyard to the cap, you need only get wet once."

Valve Maintenance

Marelon® is a proprietary formulation of polymer composite compounds using composite glass and/or carbon fiber reinforced polymers and additives to produce a superior marine-grade product. For use above and below the waterline
www.forespar.com
 
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Tom J

Tom J

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Sep 30, 2008
2,319
Catalina 310 Quincy, MA
dave_and_dd said:
It does say to cycle them at least every month. (some of mine i'm guilty of not doing this).
Click to expand
Some of my seacocks I cycle every time I leave and enter the boat. Others, like the macerator, I'm guilty of cycling only a few times a year. I did pick up a spray can of lubricant for the Marelon valves and will be doing that this season. So far, no issues with any of the valves.
 
C

CarlN

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Jan 4, 2009
603
Ketch 55 Bristol, RI
Do you have the Forespar Series 93/OEM style (picture below). If so, I have found they don't need lubrication. I do "exercise" them twice a year by opening and closing them fully 3 times. And while not necessary, when the boat is hauled for some other reason, I'll put a dab of forespar grease on the ball from outside the boat with my finger and cycle the valve a few times - can't hurt.

The other Forespar valves do need regular and careful lubrication.

The Series 93 will develop two kinds of minor (non-dangerous) leaks. The first is that the caulking around the thru-hull will fail from age and weep. The 2nd is that an o-ring in the handle will start to leak. Forespar will sell you new o-rings. In both cases, no need to think about it until you see dampness
 

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D

dave_and_dd

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Apr 13, 2015
157
Catalina 309 Port Charlotte
Thanks for the replies folks...

Yes these are the Series 93 seacocks (and generally don't require any lube - just exercise). This one has developed a drip (when open). So looks like it is likely the o-ring from your description. I'll get replacements and see if that helps.

I'm assuming taking the valve apart and replacing the o-rings is straightforward? anyone know of any exploded parts diagram on these? I will be doing it when I pull the boat out of the water in a couple months (but understand that they can be done in the water if you plug the outside of the through hull.)

thanks,
Dave
 
Ward H

Ward H

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Nov 7, 2011
3,774
Catalina 30 Mk II Cedar Creek, Bayville NJ
I installed the Marelon Series 93 thru hull valves in 2019. I exercise them 2 to 4 times a month. From new they operated stiffer than I expected them to. The second 2nd season of use they are so hard to operate I'm the only one who opens and closes them,
I too thought they were maintenance free and had planned to change them out for bronze until I read on the Forespar website they should be lubricated occasionally dependent on use.
I also found they operated easier this winter when out of the water. Not sure why that is. I'll be lubing them before launch and every 4 - 6 weeks this season to see if operation improves.

@dave_and_dd I agree that I would do this out of the water, just to be safe. You might want to talk to Forespar tech support. They were a big help in answering my questions when I was considering purchasing the thru hulls and valves.
 
Parsons

Parsons

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Jul 12, 2011
1,165
Leopard 40 Jupiter, Florida
What's the failure mode on these seacocks? My macerator sea-dump through-hull has never been exercised in 20 years (former Great Lakes boat). I tried moving it recently and it rotated, but started leaking around the handle. The hose and hull mount look fine, so I do not think it will be a boat-sinking failure, but I'd rather not find out. How do they fail?
 
JamesG161

JamesG161

SBO Weather and Forecasting Forum Jim & John
Feb 14, 2014
7,745
Hunter 430 Waveland, MS
I plan to change all of my Apollo bronze valves, since I am restoring my boat.

1) What Series Marelon Valves are recommended for Salt water service?
2) I am confused about their thru hull recommendations, that have no "strainers". Mine match the Apollo seacocks.

Any help would be appreciated.
Jim...
 
JamesG161

JamesG161

SBO Weather and Forecasting Forum Jim & John
Feb 14, 2014
7,745
Hunter 430 Waveland, MS
Parsons said:
but started leaking around the handle
Click to expand
What model valve do you have?

Sounds like the packing around the handle to ball valve stem.
Jim...
 
Parsons

Parsons

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Jul 12, 2011
1,165
Leopard 40 Jupiter, Florida
JamesG161 said:
What model valve do you have?
Click to expand
Great question - it's the original that came on my Catalina. The bottom part is glassed in fully, and it's behind/under a host of tubing and AC ducts aft of the waste tank - I can't see it fully. It looks similar to the Series 93, linked above, but I really couldn't swear to it. In the end, I'm guessing that all Marelon seacocks are built similar, so it may not matter.

If it's the packing that's merely old, then how do I deal with it? She's in the water, and it's half a boat-buck to pull her even for temporary work. If I open it and it leaks, will it continue to leak once I close it? I'm OK with draining a gallon into the bilge during a waste dump, but not if I can never stop the leak.
 
D

dave_and_dd

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Apr 13, 2015
157
Catalina 309 Port Charlotte
Parsons - if it's the original valve to the Catalina, I understand that it's likely the 93 series OEM valve. Apparently they have resisted selling that via retail because it has some different threading that they don't want folks to try to mate to other fittings. there's various info on the forespar site.

They say you can do maint on them while in the water. They each have a plug tucked into the handle that you can pull out and stick in the outside through hull (with a lanyard attached, so when finished you just pull - only one dip in the water).

I have heard of 2 failure modes, 1 (as mentioned above) minor leaking (like mine). Everyone says to replace the o-rings to fix. 2 some have broken the handle off if the valve get too stiff and is operated.

check out the following you-tube from a guy replacing his broken handle on one:


Dave
 
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Tom J

Tom J

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Sep 30, 2008
2,319
Catalina 310 Quincy, MA
Parsons said:
What's the failure mode on these seacocks? My macerator sea-dump through-hull has never been exercised in 20 years (former Great Lakes boat). I tried moving it recently and it rotated, but started leaking around the handle. The hose and hull mount look fine, so I do not think it will be a boat-sinking failure, but I'd rather not find out. How do they fail?
Click to expand
See prior posts concerning o-rings, but Dave has an excellent description of the fix.
 
Last edited:
Ward H

Ward H

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Nov 7, 2011
3,774
Catalina 30 Mk II Cedar Creek, Bayville NJ
Depending on the age of your Catalina you may have the Marelon 850 ball valve. That’s what I had on my 93. The 850 series is prone to broken handles that allow the ball to fall out. The OEM Series 93 are built much tougher and the design was changed so if the handle breaks the ball remains inside the valve.
Here is a link to thread that has videos of testing both types of valves.
Marelon Series 93 Testing

@JRT Thanks for the link. I’ll put some on order.
 
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