Best Of
Re: Observations on my old, rotted out wet return.
You're missing the whole advantage of copper: it doesn't rust. Since I replaced the black pipe with copper, my boiler stays much cleaner. I never realized how much rust was forming in the wet return before I installed sight glasses on the drips and could see that it's perfectly clear, clean water before it gets into the wet return. With copper, it stays that way and my boiler water stays clean all winter.
Re: Observations on my old, rotted out wet return.
Copper is fine below the water line simply because there's no negative for it there, and there is a good reason to use it, its corrosion-resistance.
The dead men were just men
Re: Observations on my old, rotted out wet return.
What's your speculation. Was the pipe rotting from the inside out or from the outside? I have seen both. Bet you have too.

Re: Replumbing: Solder or Threads for Ball Valves
Okay, Back to the original question of sweat vs threaded connections for valves. My approach has long been to use threaded valves, as valves eventually fail. If I can build things so a torch is not needed the next time around, that's a plus in my mind. 😇
Yours, Larry
Re: System 2000, nearly double the cost of Weil McLain, is it worth it?
@EdTheHeaterMan OK thanks. So in your estimation, maybe 15% of the EK savings may have been due to getting rid of the tankless coil, and the other 20% to the other efficiencies of the EK?
So in the OP's case, where a tankless coil is not involved, if the OP is saving 20% per year on 1235 gallons of oil, at $3.50/gal that's a potential savings of about $850/yr.
I still think a new Weil McLain with no coil is going to be within 10-15% of an EK, so I would peg the probable savings at a lower number, with the 20% as perhaps an upper limit for potential savings in this case, where the homeowner is not replacing a tankless coil or indirect.

Re: Cold only leak?
probably the tankless heater gasket. It is common for them to leak when cold as the gasket gets old it loses it elasticity.
Re: System 2000, nearly double the cost of Weil McLain, is it worth it?
Thank you, @Hot_water_fan . Idle loss is a characteristic of boilers and has particular relevance with oversizing impacts, load profiles, and annual efficiency. Steady state thermal efficiency and idle loss together provide very good insight into how boilers will perform in the field, so I would say that the study is very relevant and important for making and informed decision.
Roger

Re: System 2000, nearly double the cost of Weil McLain, is it worth it?
I find that hard to believe. Can you give some examples? Tech Support saved my butt a few days ago. And I only waited 2 minutes. I didn't go into a que hole for 3 hours and need to have model and serial numbers of everything before I was connected. I'm also pretty sure my Territory Manager covers your area, and there couldn't be a nicer guy. So justification is needed.

Re: Replumbing: Solder or Threads for Ball Valves
I thought we were talking about the entire system.
I mean, the thread is about replacing valves………

Re: Experience I had with a boiler tech and what I learned along the way.
Some of this depends on how the companies are structured as well. There's a few companies in the Detroit area that have a high turnover rate of employees. I have gone behind some other companies and explain my findings to the homeowner where they say what they didn't catch that. I find some of the companies where they give commission to techs more times that not are the ones to stay away from. The tech is more focused on getting to the next call and sell parts so they increase their commission. Train and pay guys so they focus on quality rather than quantity of calls.