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Wildbuckaroo · 05-20-2022, 09:16 AM

Hello everyone, I've removed my aqua hot model AHE-100-04S and stripped it down to the bare tank because it was leaking out the coolant recovery bottle for the aqua hot with the water pump on, so I know the problem is inside the tank. Now my question is, has anyone ever cut the tank open to service and repair it and if you did, do you know where to cut it? I searched but couldn't find anything on the forums and was thinking of cutting the weld at the end of the tank where all the hoses and lines hook up. I know you can buy rebuilt ones from John but I'm a automotive and heavy duty tech and like to do all my own work if I can and if I can't I will buy one. Thanks for any input.

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gjames50 · 05-20-2022, 09:30 AM

Not exactly sure, however if you check out the follow forum link, someone actually cut one in half to show what it looks like inside. This may help you determine where the best place to cut it would be.

I think you are right that cutting the weld on the flat side end where the pipes are passing through should achieve what you want. It appears if you cut there the assembly will pull out of the tank.

Good luck!

https://www.monacoers.org/topic/668-...ge/2/#comments

wamcneil · 05-20-2022, 10:28 AM

Yeah, seems like if you ground off the weld, everything you need to access will pull out of the tank. Then clean up the edge of the flat piece and weld around the outside again.
I sure hope I never have to do that...
Hope it works out well!
Cheers,
Walter

Flyer15015 · 05-20-2022, 10:36 AM

That is exactly where I would cut..........

vito.a · 05-20-2022, 12:00 PM

We've had at least two guys rebuild their Aqua Hot boiler. They posted extensive pictures. Hopefully someone can locate the threads.

Wow, just getting it out is a big job! Good luck!

Wildbuckaroo · 05-20-2022, 12:11 PM

Quote:

Originally Posted by gjames50

Not exactly sure, however if you check out the follow forum link, someone actually cut one in half to show what it looks like inside. This may help you determine where the best place to cut it would be.

I think you are right that cutting the weld on the flat side end where the pipes are passing through should achieve what you want. It appears if you cut there the assembly will pull out of the tank.

Good luck!

https://www.monacoers.org/topic/668-...ge/2/#comments

Yes I seen those pictures and that one would have the coils wrapped around the outside but my model is a bit different all the coils are on the inside.

wamcneil · 05-20-2022, 01:00 PM

What are you looking at? The cut open pictures in that link show internal coils, not external...
Edit: oh wait, sorry. I thought the pictures were of the unit the guy was replacing. I see now where the poster says they are from the old style with external domestic loop.
Cheers,
Walter

gjames50 · 05-20-2022, 02:11 PM

Quote:

Originally Posted by Wildbuckaroo

Yes I seen those pictures and that one would have the coils wrapped around the outside but my model is a bit different all the coils are on the inside.

Even so, I can't image the internal coils would be attaching inside. I think everything would attach to that end plate where the tubes pass through.

I believe you will be OK. I couldn't find any other pictures either.

Good luck!

153stars · 05-20-2022, 08:32 PM

If the weld has extra build up /bead. I would cut just at the edge of bead for straight through cut, not deal with splitting a weld on tank. The old bead will have extra metal to weld up to.

thedoktor · 05-23-2022, 07:17 PM

We did that on our 2004 Sig with the same unit. That is the end you want to cut as it will expose all the internals.

Wildbuckaroo · 05-24-2022, 06:30 AM

Quote:

Originally Posted by thedoktor

We did that on our 2004 Sig with the same unit. That is the end you want to cut as it will expose all the internals.

I am ready to do it now and I rolled it over on its side and the exhaust is on the bottom right by the weld I’m cutting but I guess I would just cut around it and leave it attached to the front of the tank

Wildbuckaroo · 05-25-2022, 09:45 PM

Well I have it all apart and the tank cut off successfully. I found two lines rubbing together and everything else looks good. I just have to apply a solder repair to the lines and configure something to eliminate the rubbing. I feel that this is an actual design flaw and that probably most of the failures are caused by this very same thing.

Windward · 05-25-2022, 10:02 PM

Quite the maze of tubing!

I'd silver solder, not regular solder, the tubes individually then silver solder them together to prevent it from happening again. While it is apart you better look for more rub points, it looks like there may be more in that coil.

I've had rub problems on coolant lines and did some extensive searches for rub points/line damages. I guarded them with a split hose and tied everything down to prevent future issues.

Well done!