Ever have one of those projects where everything you touch goes wrong ? Well that is what happened while working on the genset (generator for making electricity when solar is unavailable). The genset just ticked over 1000 hours so it was time for some major maintenance. I haven't ever changed the impeller (rubber vane device that pumps in sea water for cooling) so it was about time. The pump assembly was nearly against the starter motor, so it had to be totally removed. It was mounted with a combination of metric and US bolts so it became an hour long guessing game to determine proper sizes. The cover was attached with Allen bolts...I couldn't find the correct size and had to borrow one from friends on 'Joanna'. (another 1/2 hour). Of course the impeller was seized in the housing and had to be manhandled to get it out....(add another 3/4 hour which included finding the bandaids). I dropped a part (half the size of a dime) which keeps the impeller from free-spinning into the bowels of the engine...add another 20 minutes to find it...and another bandaid. Reassembly was uneventful, but took nearly an hour. OK, time to see if it works....I pushed the start switch and nothing but the sounds of silence !! WTF !!! I pushed it again....NOTHING !! I pulled out a small mirror on long handle to take a look around the starter circuit. Yup, a wire was hanging with a plug on the end...but where did it belong ?? Add another 30 minutes of searching for a lonely male spade connector. Finally, I found it on the rear of the starter circuit. Add another 20 minutes of turning into a contortionist it get it back in place. I hit the switch and the genset leaped to life....YIKES....I'm soaked....a hose had been loosened by accident, and it was spraying gallons of seawater all over me, and the genset. But worse, the deluge was aimed squarely at the back of the electronic panel for the solar panel charge controller....As I watched, I could see the circuit board frying and the LED lights going off one by one.... &^$+@# !! Cleaning up the saltwater took another hour. The next day you have to add another 3 hours for a trip to Budget Marine for a new controller for $350.00 US and the installation. What should have been a 15 minute project took nearly 10 hours and hundreds of dollars !!.... Some days it just doesn't pay to play mechanic....law was more fun, and cheaper !!
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