New Return Options

CaptPaul

I am in the process of replacing the return on my 1960's era American Standard A-3 boiler. The old return ran from the back left to the front and crossed under the oil gun to a connection on the bottom right of the front of the boiler. The gun sat on the pipe and there was lots of galvanic corrosion.

I might go around the back of the boiler and up the right side or I think I might be able to use an alternate feed hole in the back. If I could, the repair would be neater.
As the pic will show, it is a plug with a 1-1/2" countersunk square in the middle of it. The original knockout in the cabinet is still in place and it looks like like it has never been opened. I have had success breaking a 3/4" plug loose that was in the same condition.
I have 2 questions. Is there a tool available designed for this and what are the odds of being able to get it out successfully?





Any input is appreciated.

Steamhead

Don't even think about it. That plug is very happy where it is. Come around the back and approach the existing return from the right side of the boiler so it doesn't run under the burner.

What burner is on that boiler? Not the original I hope?

CaptPaul

It's a Beckett. Older model but not that old. It runs very well.

EBEBRATT-Ed

you can get the plug out by drilling a big hole in it and cutting the plug in pieces (with a sawzall) like a pie. carefully so as not to hit the threads. but as @Steamhead head said it isn't worth it just pipe around the boiler

clammy

Just wondering is there a jacket to that boiler or was she just a stripped down as we see it . I will have to tip my hat to you most wouldn’t bother attempting any real repiping on a 70 + boiler of any sort and most likely update . I would image that using a high speed burner on a older oil boiler which was originally designed and used a low rpm gun would not offer the best eff numbers unless properly baffled to lower the draft through the boiler an of course lower the stack temp . Not to sound negative but nothing last forever and w oil not as cheap as when that baby was put in unless she sipping that oil like tea sooner or later she will see a sunset hopefully on some ones else check book
Peace and good luck clammy

BobC

I came home from Korea in Feb of 1970, we were paying 17.9 cents a gallon for $2 oil from a big outfit. That fall I switched to guy down the street who selling it for 13.9 cents a gallon. The lowest cost in this area now is $3.79, i switched to gas back in 2013.

Shows how far the dollars worth has dropped in almost 43 years

dabrakeman

Should be a guy down the street selling it for $1.10/gallon today if based upon inflation alone.