1801 Scupper tube replacement

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tomc585

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2003 1801 Getting ready for the season doing some preventative chores. I noticed the brass scupper tubes are getting some corrosion inside. It looks like it measures about 1.25" inside dia.
Looking for advice on going with the brass or keep it simple and use a plastic replacement. I'll need to do all 4

Seeking size verification and brand/source.
 
Simple thing to change. Make, barrow or buy the tool.
Most of the replacement inserts come long, cut to length with a tube cutter

1 1/4 X 3” long was the size on my 2007 2120 - less than $15per tube
 

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4200 whole channel, use masking tape with hole cut out with outer lip diameter. I slightly enlarged holes and epoxy sealed them first.
 
You can do all that.....Or find the right size Gray PVC ....Overbore the hull and bed the PVC in epoxy/Cabisol. Which I have done a bunch of times. The PVC is cut slightly short of the thickness of the transom....This allows for a nice fillet to be created at the exposed ends. It will never need repair again....It will never leak....
 
You can do all that.....Or find the right size Gray PVC ....Overbore the hull and bed the PVC in epoxy/Cabisol. Which I have done a bunch of times. The PVC is cut slightly short of the thickness of the transom....This allows for a nice fillet to be created at the exposed ends. It will never need repair again....It will never leak....
Wart, good tip on the gray PVC, I’m assuming you mean the electrical conduit stuff? I used typical white PVC, which seemed like overkill.

tomc, bear in mind that going the PVC route you’ll likely need to plug the old scupper holes with dowels, then re-cut the holes to the correct size. This can be a bit tricky to get exactly straight unless you’ve got one of the handheld drill press units. The transom is THICK, you’ll probably have to do it in at least 2 cuts with a hole saw.
 
Wart, good tip on the gray PVC, I’m assuming you mean the electrical conduit stuff? I used typical white PVC, which seemed like overkill.

Yes Gray / Electrical stuff, because of it's UV protection
 
Finally got around to removing the scupper tubes today. They actually came out easier than I had antisipated.
I used a hacksaw blade with a handle to cut a slit in the tube just enough until i hit sealant. (made it a lot easier and less chance of damaging the gel on the other side)
A tap with a chisel and a pair of needle nose vise-grips and they twisted right out, most of it anyways.
A 21mm Snap-On 1/2" drive deep socket helped knock the remaining piece out the other side.
Round wire brush cleaned out the old sealant pretty good.
Nice to see the transome core is dry and solid.
 

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Why is it that it always rains when you plan boat maintenance?
Finally got around to epoxying the scupper holes yesterday and today I did a second coat for good measure. Almost seems pointless now to install the tubes. Over drilled and epoxied the screw holes also.
4 New FlowMax ball scuppers arrived today, hopefully I'll get them installed tomorrow.
 

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Here's a fun fact. Never assume. So I over drilled and epoxied the holes for the scuppers. The new FloMax ball scuppers are the same hole pattern as the existing holes so I drilled pilot holes into the center of the epoxied holes and installed the 1st ball scupper plate. On to the next 3.....it aint happening. The drain tubes are slightly off a bit compared to the 4 screw hole pattern in the transome. There is a recesse in the new scupper mounting plate to accept the lip of the brass tube. The old flappers weren't centered which threw the holes off a bit. Refilled with epoxy and will have to wait to finish another day.20210507_141515.jpg
 
Looks like another set-back today. I was mounting the 4th and final ball scupper today and I ended up with 5 (yes 5) broken screws in the transom. Guess I'll be shopping for a hollow screw extracter to bore them out, epoxy and start again.....uggggg!
I had all 4 started and seated. The last one broke off inside the transom, nothing to grab on to and too small to drill. When I went to take off the scupper the remaining 3 broke the same way. Since there's 2 sets of holes on the scupper I tried to mount it and the first screw broke. Wasn't like I was using home depot hardware. Started out to be a nice day.
 
Looks like another set-back today. I was mounting the 4th and final ball scupper today and I ended up with 5 (yes 5) broken screws in the transom. Guess I'll be shopping for a hollow screw extracter to bore them out, epoxy and start again.....uggggg!
I had all 4 started and seated. The last one broke off inside the transom, nothing to grab on to and too small to drill. When I went to take off the scupper the remaining 3 broke the same way. Since there's 2 sets of holes on the scupper I tried to mount it and the first screw broke. Wasn't like I was using home depot hardware. Started out to be a nice day.
This seems... very odd. These were the new fasteners? One broke when it was being driven in, and the rest broke when taking them out?

Did you pre-drill the holes in the epoxy? Not just pilot holes, but holes to the proper dimensions for the fasteners? How much torque were you putting on the screws when they broke?

I can honestly say I've never heard of this happening on this type of install... where DID you get the hardware?
 
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