SV Pilgrim - 1979 Morgan 382 - Homeport: Beaufort, NC

Monday, December 29, 2014

Dissecting the Ice Box Reveals Morgan Construction Shortcomings

Here is a link to part one – Removing the Original Ice Box

I expected to unveil the cause of the leaking drain that initiated the ice box rebuild, I did not anticipate to discover…
Exterior of ice box drain fitting... and yes my foot is resting on the starboard engine bed in the background.
The fitting between the ice box and the drain hose was a 90⁰ hose barb.  Standard fare on the discharge end – a hose held in place with a stainless hose clamp – all good here.  At the ice box end - the hose was set in the box via a coat of epoxy painted atop the insulating foam.

The interior of the ice box drain fitting.  The flat surface was pressed against the exterior of the ice box.

The end of the hose barb was cut flush with the wall of the box.  That is it.  No mushroom head fitting.  No threads tapped into the box.  No caulking.  I have to believe this fitting has leaked since hull #115 rolled out of the production shed.  The mold in the insulation surrounding the drain fitting serves as additional evidence of a 35 year old leak.

Once all the ice box pieces were excavated and the last of the insulation crystals sucked into the shop vac, I marveled at a complete lack of tabbing between the hull and any of the surrounding cabinetry.
Looking forward through the ice box compartment at the unsupported 1/2" plywood wall below the galley counter top.

The wall forward of the ice box that forms the face below the counter top in the galley is unsupported for all but the lowest six inches.  The last six inches of the vertical panel (closest to the companionway) rests atop the cabin sole but is not directly fastened to the sole.  I cut the five inch circular hole at the lower right during my early attempts to replace/repair the ice box drain.  I will fill it later in the re-build.
Looking through the lid of the ice box at the unsupported base of the mid-ship, vertical wall that divides the ice box from the engine compartment.

The wall separating the ice box from the engine compartment also lacks tabbing to the hull and is unsupported along its entire length.    This opening allows hot air from the engine compartment direct access to the poorly insulated underside of the ice box – ridiculous!  The black mold in the image above is the remnants of the colony growing around the leaking ice box drain.

Time to purchase more 1708 cloth… TO BE CONTINUED.

Here is a link to additional images and notes – Ice Box Rebuild Photo Album

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