DF520 Return Ports: Bushing'd to Different Size: ? ? Matter?

New to the NE and new to paying the absurd price of heating oil and I'm ready to join the anthracite club!

I am in the process of installing a df520 circa 1981. The return ports both have bushings in the original welded bungs. The port on the right (when facing the boiler) is 1 1/4 the one on the left is 1". I plan on using both as is recommended. The pump will be on the return placed on the right side and my plan is to use all 1 1/4 black pipe.

I tried to remove the 1" reducing bushing with a pipe wrench, PB Blaster, and heat to no avail. It was sealed with something pipe dope?

Question: How big of deal is it if I simply plumb it using a 1 1/4 "T" on the right hand return, use a reducing bushing to 1", nipple, union and a 1" T on the left hand return?

Question: Assuming the first answer is No big deal...What are the chances that I didn't screw up the deal when heating the bung and busing while trying to remove it? What should I pressure test it with?

Question: It the question to number 1 is they need to be the same any suggestions on how to remove the bushing that has been in there for 20+ years.

I look forward to hearing your expert answers as the sooner I get this up the sooner I can start saving money and making my wife happy for not complaining when she goes over to the thermostat.

Thanks,

Roger

Welcome to the forum. I also have a 1981 DF520, and it came bushed down to 1". A 3' pipe wrench got the bushibgs out of mine, but it took a lot of torque to break them loose. You need a big wrench with a big guy on the end of it...otherwise you will have to cut them out, and that is nerve wracking.

Your proposed piping arrangement may work fine, but I would try to get those bushings out and start fresh. I have had old ones leak before.

If this boiler is going into a house, I wouldn't worry about the 1" bushing. I easily heat my house with a hand fired boiler using 3/4" pipe. If you want to remove it, use a saw and cut into the bushing threaded area until you are about through to the welded bushing threads. Then use a small sledge and punch and hit the bushing from the side to break it. I doubt that you injured the old bushing at this point.

Thanks for the reply guys!

I ended up cutting the bushing with a sawzal in two places and used a chisel to get it out. It always feels better to know you are doing things right.

Thanks,

Roger

Worcester, PA... Howdy neighbor!!! Waving a hand from Skippack!!!

Seven wrote:It always feels better to know you are doing things right.

It sure does. If you don't have time to do it right the first time, how will you have time to do it twice?