Fishing with the Matador's video: Cummins qsb 5 9 420hp to 480hp MOTOR SWAP Henriques single engine Maine Coaster Downeaster 27kts

.9 September 29 2020, I was riding out to the fishing grounds with a charter on board on my Henriques 35 Maine Coaster "Toro" when at cruise the motor (@CumminsEngines qsb 5.9 420 hp appx 4200 hours) made a short but loud grinding sound, lost rpm and began smoking. I took the boat back to the dock and unloaded the charter, diagnosed the problem as a dropped valve. Cummins "B" series motors are not a wet liner style motor, so rather than pull the motor and have a cylinder drilled, piston replaced, new cylinder head, new turbo, etc, I opted to upgrade to a cummins 5.9 qsb in the 480 horsepower rating. I called the boatyard and scheduled first available haul out and in the two weeks between dropping the valve and haul out, I would need to locate a new motor, file an insurance claim, and begin preparing the boat for haul out and motor swap. I removed the greenstick, cut the fish box off the deck, and allocated an a frame crane for the swap. On October 13th with the dropped valve, I drove the boat under it's own power from Rudee Inlet to Lynnhaven Inlet at Capp's boatworks. The boat was hauled, washed. and blocked the next day on the 14th. At about 2pm, the boat was on blocks, shore power connected, and ready for work. By 6pm on the 14th, the crane had been installed on the deck of the boat, and the old motor with dropped valve was in the back of a truck heading to a garage, where the new motor was waiting. I made some calls and was able to locate some low hour government running take out qsb 5.9 motors locally. The government contractor had about 2 dozen of these motors for sale, but only two were in the 480 hp rating. All the other available motors were in the 370 and 420 horsepower rating. So I bought both of the motors at 480 horsepower- as is. One motor would be the motor I replacement for the motor with the dropped valve, the other motor would be a spare. I got a great deal on the motors and it was hard to pass up. Both of the motors I bought were built by Cummins in 2014, installed into Navy small craft in 2015, removed from those vessels summer of 2020, then sold to me October 2020. The motors came out of two different vessels. one motor had 1270 hours. The other motor had 940 hours. When the boat was hauled, I immediately removed the old motor and took it to my buddies garage. The two new motors were waiting there and I chose to use the motor with 1270 hours as the replacement motor. After looking at the two new motors, I just thought the motor with 1270 hours was the motor closer in configuration to the motor I took out, which would make the replacement job easier. I converted the new motor to 12 volt from 24 volt by changing the starter, alternator, lift pump, and starter solenoid. I changed the front mounts on the new motor, added the proper pulleys for my configuration, changed the drive coupling, and spray painted the new motor with the same platinum Pettit ezpoxy as the hull. For insurance purposes, I broke down the old motor and stripped the head off to find a cracked and broken valve, along with a totally destroyed head, piston, and cylinder in . There was also moderate damage to , and minor damage in and . I guess while the valve breaking in destroyed that cylinder some other damage occured in other cylinders as a result of the catastrophic failure in . Either way I made the right call in fully replacing the engine as the other engine is a total loss and would be more to rebuild than it's worth. While I painted the new motor and readied it for install, I cleaned and painted the bilge on Toro around the motor (petit bilgecoat gray), I cleaned and painted the transmission to match the motor. I also prepped the bottom of the boat, painted the bottom, installed new zincs, and painted Propglide on the prop, shaft, and rudder. After a couple of days being hauled out, the new motor was ready for install and was trucked to the boatyard and crane lifted into the boat and into the hole and within a couple hours, the new motor was in the hole, fully connected, and aligned ready to go. There were very few issues with the install and the biggest obstacle was that the 480 has a much larger turbo than the 420, and I had to grind a small amount out of the housing of my Twindisc 507-1 to make clearance for the new motor. The following day, October 28, 2020 Toro was set into the water and ready for sea trial. The new motor started right away, ran clean with no obvious leaks, came to temp, and I drove back to Rudee Inlet and put the boat back in slip. Performance s 420 horsepower, boat full of fuel & gear: Cruise @2500 rpm 20.5kts, 80-85%load, 15.7 gph. WOT 2750 rpm, 24.5 kts 100% load 21.6 GPH Performance @ 480 horsepower, boat full of fuel & gear: Cruise @2600 rpm 22.0 kts, 80-85% load, 16.1 GPH. WOT 2950 rpm, 27.5 kts 100% load 24.6 GPH After shakedown, I found an issue with turbo boost tube where I was losing boost so wot # should improve. Thanks for watching.