Exhaust Hose Replacement

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WindEnsemble
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Exhaust Hose Replacement

I am about to replace the exhaust hose (muffler to stern) and was wondering if any of you had any tips for getting the hose in. Did you start from the muffler end or the stern? Did you attach the old hose to the new to assist in pulling through the hose? If so, how? Remove the galley/stern berth wall or work from the stern berth and remove the shelf? Any tips are appreciated. My searches have not turned up much, so thought I'd ask outright.

Thanks,
Jeff

S/V Wind Ensemble
1987 C-36 Wing Keel
Universal M25XP 23hp
Hull #705
Coastal Alabama

capestarr
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Joined: 12/8/18
Posts: 25

Hi Jeff:
My wife and I replaced the exhaust hose on our 1985 Catalina 36, hull 397, in January 2019.

The job took us about 20 hours over 4 days and cost $265 for the new hose.

Below are details. Attached are some pictures.
Good luck on your project.
Regards,
John

John O
The 7OCs
Catalina 36, 1985
Hull 397
Annapolis, MD area

*********************Exhaust Hose Replacement ********************

  • Purchased 19 ft Trident-Flex Marine Wet exhaust 250-1580 1 5/8' hose from Fawcett, Annapolis.
  • Used 1 1/4 PVC pipe from Home Depot inserted in new and old hose and screwed in with 4 flat head screws to snake hose through hose/wire tray
  • I removed the shelf in the aft cabin but did not remove the bulkhead between the aft cabin and the galley
  • Wife pushing in lazarette and me pulling in aft cabin allowed us to snake the hose in 1-2 hours. 
  • Cut hose with hack saw after snaked. Stainless wire in hose was difficult to cut with hack saw. Bought Klein diagonal cutting pliers; cut wire easily.
  • Bending hose down from run tray in aft cabin and up through slot was not that difficult. I didn't need to use the pull line I had rigged.
  • Used 2 @ ALBA 316 SS # 28 size hose clamps in aft cabin on aqualift muffler.
  • Fitted hose in lazarette twice and then cut with hack saw and cut wire with diagonal cutting pliers.
  • Used 2 @ ALBA 316 SS # 28 size hose clamps in lazarette.
  • Used mounting nylon wire tie to secure exhaust hose to overhead in lazarette.
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Haro
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Posts: 435

John, thanks for sharing your ingenious solution.

WindEnsemble's picture
WindEnsemble
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Posts: 98

Thanks a bunch, John. Sounds like a plan. If you don't mind my asking, what was the most time consuming part? 1 - 2 to actually install the hose doesn't sound bad.

Jeff
 

S/V Wind Ensemble
1987 C-36 Wing Keel
Universal M25XP 23hp
Hull #705
Coastal Alabama

capestarr
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Joined: 12/8/18
Posts: 25

Hi Jeff,
Snaking the hose from the lazarette to the aft cabin took the most time; and there was two of us working on it.
Other labor items with significant times were:

  • clearing out the lazarette;
  • fitting, cutting and finally clamping the hoses;
  • taking measurements (multiple times to make sure we got it right).

The boat was new to us at the time and we were slow, cautious and inefficient in doing everything.
Regards,
John O
 

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WindEnsemble
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Thanks, John. We plan to start this process next week. Appreciate your responses.

Jeff

S/V Wind Ensemble
1987 C-36 Wing Keel
Universal M25XP 23hp
Hull #705
Coastal Alabama

pierview
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Joined: 9/27/09
Posts: 598

Jeff...
I did this years ago and I found it helps to have the right crew to help. I'm 6'2" and lets just say north of 200#. My wife is vertically challenged, about a foot shorter than I and I'm too gentlemanly to mention weight but she's thin.. She actually got into the port locker and pulled on the hose while I pushed from in the cabin. 

It's possible but it was humid day and I have to say she looked like she had been swimming when I pulled her out. Just find a short, thin, helper.
 

Chuck Parker
HelenRita 2072 Mk II
2002 Tall Rig - Winged Keel
Atlantic Highlands, NJ

HobieDog
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Joined: 12/4/24
Posts: 1

I am in the middle of replacing my exhaust hose and see that the hose makes a loop behind the port lazarette, just after it comes up from below. 

have not seen this loop mentioned elsewhere so I'm wondering if it is necessary.  Photo is from the stern lazarette looking forward. 

1989 C36 MKI Tall Rig
RI, NH, ME

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Haro
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Jeff, my C36 is 1999 version and hose I replaced is 12 feet long. I did the job by myself. I started at the stern and pushed the hose towards the muffler.
Yes, the loop is needed which goes above the waterline to prevent siphoning and flooding the engine.

capestarr
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Posts: 25

Regarding HobieDog's question on the loop for the exhaust hose in the lazarette.

I kept the loops.

On my boat the exhaust hose goes up from where it exits into the lazarette from the hose run behind the aft cabin on the port side. From there its secured with ties near the overhead on the port side, runs aft to the aft bulkhead and loops around the aft bulkhead. It then goes down to the through hull fitting to the outside.

This was the routing of the hose when I started the project and decided not to change it.

I don't know if this is necessary. In my opinion this routing of the hose has the benefit of keeping it secure and out of the way when you need to get into the lazarette to do work such as servicing the steering gear.

Good luck with your project.
John
1985 C36 Mk1, Hull 397

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WindEnsemble
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HobieDog,

I am guessing the loop in your installation is more for limiting following seas from getting to your muffler. It's not an anti-siphon. That should be on the smaller hose between the heat exchanger and the mixing elbow. You just need some up/down in the exhaust hose to discourage seas coming in from the stern. A loop (as in your case) accomplishes this as well. The more "up" from the exhaust through hull the better. If water does get in, the anti-siphon is supposed to prevent flooding the engine. Belt and suspenders. Mine does not have a loop, but it does go straight up from the through hull to the deck joint (about 2 feet?), then follows the deck joint along the port side. It then comes down the hull just behind the ice box, under the ice box for a couple of feet,  then through the aft cabin wall to the muffler. It took approximately 16' of hose. This was the original route of the hose. I used John's idea of connecting the old hose to the new with a short piece of PVC and dry wall screws. My wife and I then pushed and pulled until we got it in. It was not easy as some of the turns are quite tight and through holes in fiberglass. I had to enlarge the hole in the aft cabin wall to facilitate that turn. A dremel tool worked well for this and my ugly cut is hidden by the shelf that covers all of the exhaust components. Good luck!

S/V Wind Ensemble
1987 C-36 Wing Keel
Universal M25XP 23hp
Hull #705
Coastal Alabama

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