Deck/Hull Joint Leak - engine damage

[ctag1003]

Hi, i just joined so that i can ask for some opinions. I am not up on the proper terminology but I think you will understand. I purchased a new 260 Sundancer in 2006. From day one I complained to the service department about water in the bilge and rust developing on risers and other parts of the engine. I was told by the dealer that it was normal for risers to "sweat" and cause rust. Cleary, I trusted the dealer and my mechanic. However, during the time that i have owned this boat i have had three alternators, three starters, broken belt pully's, been towed in to port twice, and changed the risers. There have been other repairs as well which appear to be directly related to salt water and corrosion. I have been told that the risers need to be changed again. This past weekend I experienced a stalling engine and non responsive engine (as if flooded). I made it back to the dock and found no significant water in the bilge. I called my new mechanic and we sea trialed the boat with the engine compartment open and discovered LARGE/HUGE amounts of water seaping into the engine compartment starboard forward three feet from the transom then around the transom to about three feet forward port steadily pouring in from the deck/hull joint while at cruise speed flooding the engine compartment. The water was hittig the belt and spraying everywhere. Once the boat slowed the water would stop pouring in and the water would be pumped out. (hence the leak was never found by Sea Ray or my prior mechanic). I have been told that this is a manufacturing defect from Sea Ray. It is my opinion that the boat now has very little re sale value due to the salt water damage caused to the engine. It is also my opinion that the useful life of the engine is significantly reduced. What if any remedy should I be seeking from Sea Ray? Is this defect common? What hidden damage can be cause to the engine from ingesting 5 years of salt water. Thanks for any input...FYI Sea Ray said that are making a claim and have requested repair bills and estimates for repairing the existing condition...I think the estimate should be for a new engine!!! Given the present condition, how would I ever be able to sell my boat?

 

[jason78]

I dont know if I would classify it as a "common" problem with 260s but let's just say you are not the first to post problems like this here with a 260DA.

Not trying to be harsh but you say you bought the boat new in 2006 and you basically have put up with these problems for 6 years and just now seeking recourse from Sea Ray, so not sure what they will do for you. I am not trying to defend SR because they have obviously had some problems with caulking on a number of different boat models (based on feedback here) but I think given the time lapsed, either your dealer, mechanic, or with all due respect, you, bear at least some responsibility for this not being addressed sooner. In the end you trusted your dealer who I think should now step up and try to help you.

Again, I don't mean to be harsh but that is my opinion. I do wish you the best of luck resolving your problems. In all honesty, as long as the engine is in good operating condition now, I am not sure how much your resale would be reduced. A salt boat is a salt boat and it is no secret they require more maintenance.

As far as the repair, I believe someone else here with a 2006 260DA was able to get either SR, the dealer, or both to repair his 260DA due to lack of caulking last year. I think you have a pretty good case for the same. If I can find his thread, I will post it. I doubt they will replace the engine, particularrly if it is is running but I have been suprised before.

 

[ctag1003]

thank you, no offense taken and for the most part I agree. I did notify sea ray and for years they gave me the same answer. They even sent techs to look at the boat. My mechanic alleged that he sea trialed the boat every year and found no leaks. Unfortunately for me I put too much trust in others and when repair was required I was told normal wear and tear. If the boat hadn't stalled the problem would have continued. It's my fault for having to much trust in the people that were being paid. Thanks for the reply. I believe sea ray is taking the claim and will make the appropriate repair. They have asked me for all bills relates to this defect.

 

[jason78]

thank you, no offense taken and for the most part I agree. I did notify sea ray and for years they gave me the same answer. They even sent techs to look at the boat. My mechanic alleged that he sea trialed the boat every year and found no leaks. Unfortunately for me I put too much trust in others and when repair was required I was told normal wear and tear. If the boat hadn't stalled the problem would have continued. It's my fault for having to much trust in the people that were being paid. Thanks for the reply. I believe sea ray is taking the claim and will make the appropriate repair. They have asked me for all bills relates to this defect.

Ok, if you did notify Sea Ray directly previously, I would be fairly confident they will address it. As I said, this has been brought up before by others so definitely not the first time they have seen it. Please let us know the outcome.

 

[Dave S]

I had the same problem with mine since new as well. This year I finally saw where the water was coming in and my dealer contacted Sea Ray who covered the repair. They removed my rub rail and found a void on the starboard side at the hull to deck joint. They repaired that and the bilge has been dry ever since.

There is another CSR member on our lake (Kendall) who also had the same problem. When he was taking his boat to Bimini he has quite an adventure because of this. Here is his posting http://clubsearay.com/showthread.php/43462-Memorial-Day-Weekend-Bimini-Trip-Report-5-25-11-5-30-11

I never had any damage on my boat from this leak. It was more of an annoyance. Hopefully Sea Ray will cover all your rust/corrosion related damage. Your engine (internals) should be fine but if it were my boat I would want all the rust and corrosion fixed as well whether it was on the engine or anywhere else in the bilge. Good Luck and let us know how you make out.

Dave

 

[ctag1003]

Thanks for the info. Sea Ray is having the boat hauled out on Monday to inspect the joint and make any necessary repairs. They have not addressed the rust and corrosion yet and will not do so until the boat is inspected. I assume that any inspection will reveal excessive rust and corrosion because it very visible. Sea Ray also made it clear that they will not reimburse me for any prior damage related to the leak because they allege that I did not notify them. That is a fight for another day and so far I will be happy with their expedience and happy with any repair that will prevent more damage. The prior repairs are "water under the bildge" I guess. Ha ha. I did notify the service manager from the dealership about the water and was told it was normal sweating of the risers. Of course, I trusted them and let it be.... why wouldn't I trust them. I had no clue that any of the damage to my alternator, starter and pully's were the result of this problem. I am on my third alternator in 6 years, second starter and two pully's snapped off leaving me stranded at sea! (Towed in twice). I was told these were normal repairs by my mechanic...who by the way has since been relieved of duty. I will keep you all posted. Thanks again.

 

[ctag1003]

Update....i happy to finally report that Brunswick and SeaRay replaced every moving and electrical component of my engine. Effectively, everything but the block was replaced new. In addition they gave me a 3 year passport warranty on the entire boat. I believe they made good because of my persistence, documentation of the problem since year one and most notably some very good PR and customer service. Although i lost most of the season i am looking forward to Spring and hopefully using the boat as designed and without anymore fear. Special thanks to Robert Nye, Robert Parmentier, Dave Dzurilla and James Hardiman.

 

[northern]

You may want to get a structural and mechanical survey on the boat in the fall. Because you own the boat you can remove pannels and open areas that a normal survey would miss. This way if there are any other items that got missed you will find them. Nice SR came through with the repairs.
My insurance requires me to get a structural survey every 5 years so you may need one also.