KA4 Project (Pic Heavy)

Pressure test with water...
Ya just get a wet floor if she leaks...
Air testing can result in metal flying...

Qtown1835 wrote:Thanks for all the feedback. I'm going to pick up some 3/8x16 SS tap bolts tomorrow to replace the studs. Not sure if I should just do all of them or the ones that are thinned out. I will be using brass nuts.

Anyone have a good place to buy the coil gasket?

I bought the bolts and gasket from Heating World in Cresson, PA. Not sure if they ordered it or had it in stock? Wasn't too bad, though.

I replaced them all. Since you're doing it, I'd say do them all. You sure don't want to be tearing it apart down the road for the "other 3 bolts"

Called keystoker and they have all the parts I need.

Going to replace 1 of the stoker grates $80, Firedoor Insulation $9, DHW gasket $15. Im going to run up next week and grab the parts.

Another ? Does the fire door have a gasket? The ash door looks like it uses a 1" wide fiberglass gasket that I will need to replace as well.

Not from the local dealer in DuBois, PA I bought two cause I needed now-- $35 each

I got the bad studs cut off and new stud holes tapped. I ordered stainless hardware this morning with brass nuts. I need to make a road trip to pickup the remaining misc pieces so I can get the unit back together and pressure test. I may try to get this boiler on line this year.

Nice!

Shoot, if it don't need to be pretty, your almost done!

-Don

Looking good.

Looks like a nice size water jacket! How many inches wide is the fire grate? 6?

Olllotj wrote:Looks like a nice size water jacket! How many inches wide is the fire grate? 6?

Im pretty sure it's 9x14"

Looking to plumb in the boiler this way to give me some future flexibility with the current oil setup. Should minimize the amount of plumbing required too. Thinking about adding an electric water tank and using it as indirect storage in the winter then shut down stoker in April or so and just run electric for a few months rather then tend the stoker over the summer. I was planning on piping the HW from domestic coil to the CW intake on the tank. I will probably delete the taco and roll with gravity circulation. I may need some Flo checks on the CW supply?

**Sorry about the rotated pics.. Idk why it rotates them.**

Made it up to Keystoker this morning to pick up some parts. I must say that the lady at the front desk and Don were very friendly and super helpful answering questions. I had them look up the boiler in their books. This particular boiler was built in 1980, which just happens to be the year I was born, lol. Anyway, got my parts and made the hour ride back home. I stopped to pick up longer stainless studs since the ones I had were a bit too short. While I was out I grabbed some paint too.

Here are some progress pics. I'm hoping to get after the stoker unit tomorrow, clean it up and give it a coat of paint. I want to change the oil in the gear box as well while I'm at it.

Look'in nice!

Now would be a good time to try to get that second return plug out.

-Don

Qtown1835 wrote:I want to change the oil in the gear box as well while I'm at it.

Be sure to post up some pics when you do that. I have a leaking gear box and was wondering what to do about it.

Thanks!

Congrats on getting this far already!

I got the new studs in place. Removed the 2nd return bung (for Don). And got the bottom of the boiler prepped and primed. I will hit it up with a top coat later this evening. Tomorrow I am planning on installing the domestic coil, then standing it up to get it pressure tested. While the tank is holding pressure im going to tear apart the stoker assembly and give it a good once over. Does anyone happen to have the PN for the seals on the side of the gear box? Figured I would replace them since they are as old as me now...

Some more rotated pics...

This project is look'in real nice there Q. With both return ports open it gives you the option of running a crossover pipe or running the bypass into the opposite port of the system return. Either one can help even out the boiler temps.

Remember, pressure test with water, not air. I usually get about 47 PSI out of my well pump for pressure testing.

I hope it holds!

-Don