Having functioning bilge pumps and no open holes in the hull were absolute must-do items on my pre-splash punch list. The only open hole left on the hull was the OEM genset exhaust outlet. I previously posted about installing the Panda genset waterlift muffler, gas/water separator, and siphon break, but I still had to install the hose from the Vetus gas/water separator to the OEM exhaust outlet.

1-1/2″ to 2″ 304 stainless adapter threaded onto the OEM exhaust standpipe
I used a wire brush on a drill to clean the inside of the pipe, which was bare aluminum. Then I coated it inside and out with Barr Rust 235 epoxy barrier coat. I also wire brushed the OEM threads before applying Gasoila thread sealant.
It’s a strange thing: Chris Craft took the time to cut NPT threads on all of their welded in thru-hull pipes here as well as the pipes welded through the bulkheads for the bilge pumps, but then they just installed the hoses directly onto the threaded part of the pipe using hose clamps. Water inevitably gets into the areas where the threads are and starts deteriorating the bare aluminum. Fortunately, there was plenty of thread left over once I’d cleaned up the white aluminum oxide powder.

2″ 304 stainless 45° elbow connects the standpipe adapter to a 1-1/2″ stainless hose barb
So that’s a wrap for the Panda generator exhaust. Next I recommissioned the bilge pumps.

I installed a bilge pump cycle counter in the salon electrical panel
I used to own a 1967 Chris Craft Constellation 52, which had a wooden hull. You can tell at a glance if something below the waterline is letting in more water than usual, so bilge pump counters are something I really appreciate.

Refurbishing an OEM-style automatic bilge pump switch
Most boats have electric float switches to control the bilge pumps in automatic mode. But for metal boats, it’s a better practice to not have electric switches in contact with bilge water. So Chris Craft installed remote diaphragm switches like this one, which uses air pressure to turn the switch on.

I clear coated the metal parts with enamel
You can see the 1/4″ barb where a hose gets attached. On the other end of the hose is a plastic bell that’s attached near the deepest part of the bilge compartment. When water rises, the air trapped in the bell and hose is forced up, which increases the pressure at the diaphragm until it triggers the switch. The modern equivalent of this system is the Jabsco Hydro Air bilge pump switch.

Assembled and ready for installation

The air bell
The barb on the bell measures exactly 0.250″ OD, but the 1/4″ hose I bought has a .255 ID. So I need to add a bit of girth to the barb.

Liquid Tape has many uses

Next day, the Liquid Tape has cured
I’ve found you have to be patient with Liquid Tape. There are no instructions on the bottle, just chemical warning boilerplate in several languages. I find it works best if I apply it, then leave the part alone until the following day. It makes a soft, rubber-like finished coating that adheres well to plastic, metal, etc.

Stainless safety wire tie acts as a hose clamp…just in case

The bell and hose are installed behind the 1/2″ PVC pipe bilge pump pickup next to the keel.

I attached the PVC bilge pipe to the OEM bulkhead fitting under the aft stateroom floor

Air hose from the bell is attached to the diaphragm pump inlet

In the engine room, I had to clean up the threads on the bulkhead thru-pipe

I cleaned up the bilge pump thru-hull threads, too


I applied Gasoila to the clean threads
I previously wire brushed and applied Barr Rust 235 epoxy to the inside of these thru-hulls.

3/4″ hose connects everything together
I threaded a 1/2″ NPT-to-hose barb 90° fitting to the bulkhead pipe, routed the 3/4″ hose from there to the diaphragm bilge pump, then from that pump up to the thru-hull, where I used a straight NPT-to-hose barb fitting. So that’s a wrap for the aft bilge pump.

Forward bilge pump is already installed under the galley, at the forward bulkhead
I tested both bilge pumps in manual and automatic mode, and they work great.
Next up in our 1969 Chris Craft Roamer 46 Refit: Transom Door Seal






















































































































