March 8

We finally found the right guy to diagnose our generator problem. The same guy who helped fix our second alternator in Puerto Vallarta in December. If only we had asked him to look at the genset then, would have saved us a world of trouble.

The guy is awesome, his name is Scott Fratcher from the S/V Whatever (yes, his boat name is 'Whatever'). He worked the last 5 years in Alaska as an engineer on big boats and knows cruising systems, engines, everything inside out. He even can recite winding specs on any alternator you can name

When I heard him on the VHF yesterday on my way North I hailed him and arranged to meet him here today in Barra Navidad (a cool place BTW) and this AM at 11 he was here at the dock (I took a slip to make the work easier and so I could get Kate and Jonah out of our hair - sent them to the pool).

We checked everything and found several problems. The situation as it was caused rusting of the rings which now makes the genset almost useless (it's a miricle it runs at all) and needs a rebuild.

One problem which I believe was the genesis for all of this is an air leak on the suction side of the fuel system. This caused problems starting after not using the genset for more then a few days and required bleeding again. In my ignorance last September I tried and tried to start the thing WITHOUT shutting down the seacock and that is (IMO) how water entered the cylindar in the first place.

We were, however, convinced that it was from condensation. When I was in SD the maniufacturer sent a mechanic (on warranty no less) to check it out. He pulled the head after we found bad compression and found a rusted exhaust valve and rusty head. He ground the head and put in a new exhaust valve and it started fine. The he left! Never re-checked the compression for spec.

It was after THAT when I first noticed the loss of power and could not generate enough HP to put out the full 3.5kw. That was when SE power sent our a DIFFERENT GUY who found the problem was insufficient fuel delivery. The thing is, the truth is that there were TWO problems - one actually was insufficient fuel delivery -further, I now believe that was CAUSED by the air leak on the vacum side! The extra feed pump I put in actually helped somewhat and got the power output up a bit, but I never tested to see if it could go the distance and produce FULL power - I was satisifed that it produced ENOUGH to run the charger! I was (again) a fool.

After that, I noticed the exhaust leak, which, like the poor power output has steadily worstened over time. The exhaust leak is getting worse and worse, and now the power output is getting lower and lower, and of course, starting is getting harder and harder!

Last week I put in a new glow plug to help with the starting problem (again, treating the symptoms not the cause). I assume the new glow plug helped because I had burned one out from all the starting problems! So it was a combination, nay - a litany - of errors and problems, and most of all, a lack of thoroughness of the various mechanics (mostly hacks) who failed to diagnose the true problem.

Scott zeroed in on it fast when nothing after valve adjustments, removing and testing the injector, removing and testing the glow plug - which still works fine - etc., etc. we STILL had an incredible hard time starting it.

Then when we finally did get it started again he finally figured it out when he could not find the exhaust leak, till he removed the air inlet filter and found the exhaust leak was actualling coming OUT of the air inlet! Bingo. Then we pulled the dip stick and oil squirted out (not a good sign). The final test was to crank the engine with the oil fill cap removed and again, without even starting it, oil spurted out furiously from the fill cap! BINGO AGAIN!

Massive blow by, low power output, hard starting and exhaust coming from the AIR INLET (which means I think its coming OUT of the inlet valve!). All adds up to bad ring(s). Solution: new cylinder, rings.

Anyway, we have to be in PV by Tuesday for haul and paint and Scott is heading South the C. America - but there is a guy in PV who I am told can do the job, if I get the parts. Whew, what a mouthful.