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35 year old Keystoker KA6 boiler leak At ^a

Buzzber67 Member Posts: 1
Please see attached pics. This is an old unit, with many new parts. Works well, except for the leak.

This has 2 domestic hot water heating coils as an option when I bought it. A small leak started on the left coil last winter. We thought bad gaskets, so we ordered replacements from you. Yesterday we removed the coil to re-gasket, and found the hole, with a lot of metal eroded away from the leak. The hole is outside the contact area for the gasket. It went straight thru the boiler wall. It looked weak, so we poked it with a large screwdriver. The metal crumbled as the pics show.

Is this fixable ? Is there a way to repair the eroded steel part and reinstall the coil ? Could we flatten the studs and weld a cover plate over the whole thing ? We can get by with just the one coil.

Is there anyone in my area (Mountain Top) who could fix this for us ?



  • Jamie Hall
    Jamie Hall Member Posts: 17,025
    If this really is 35 years old... it's done it's time. Have you thought about replacing the whole thing with a newer, more efficient unit?

    That said, it that is really steel and not cast iron, it is weldable. By someone who really knows what they are doing. Basically the edges of the hole are ground away to sound metal, then the hole filled in with multiple passes, then the area stress relieved, then the resulting fix ground flat.
    Br. Jamie, osb
    Building superintendent/caretaker, 7200 sq. ft. historic house museum with dependencies in New England
    HVACNUT Member Posts: 4,187
    Where'd the jacket go?
    Save the aggravation and replace the boiler and assuming the burner. If things are tight you can get another steel boiler. However, an indirect water heater vs. the coil will save fuel.
  • Steamhead
    Steamhead Member Posts: 14,832
    IIRC, the Keystoker is a steel, coal-burning boiler. Coal-burning replacements are harder to find than the usual oil- or gas-fired units, so getting it welded might be the way to go.

    @Buzzber67 , where is Mountain Top located? And is this a steam or hot-water system?
    All Steamed Up, Inc.
    Steam, Vapor & Hot-Water Heating Specialists
    Oil & Gas Burner Service