Rusted Condensation Tray Under AC in 28 TE

[Bluewater]

I’ve been ignoring this for too long. Has anyone had the same problem and, more importantly, how did you fix it? Many thanks in advance.

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[Norseman]

Ouch, saltwater leak..?

[Bluewater]

Ouch indeed. No leak to my knowledge and so far limited observation. Strange thing is that the remainder of the tray is basically sound. Hard to know how to fix it without major open-heart surgery.......

[RobS]

A functional but not aesthetic solution: You could have a custom pan made to the outside dimensions of your current pan, lift the unit, slide in the new pan and drop the unit down in the new pan. Only tricky part will be the condensate line fitting but nothing an epoxy couldn't take care of. What it looks like to me was that whoever installed the a/c unit did not pitch the unit so the drain line connection was the lowest point. Here's the a/c unit in my 28te, you can see the foam wedges I installed on the side opposite the drain so she fully drained. The other thing is to not break the protective enamel finish.

[Bluewater]

That’s such a clean installation, Rob. Was that unit the 2000 original? Thanks for the comments and ideas - I figure that this is an early winter job.

[RobS]

She was not factory equipped. That was a fresh install I did. The A/C unit did look just as good the day I sold her 5 seasons later.

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[Norseman]

. No leak to my knowledge and so far limited observation.

Ok, so you are saying only fresh water from condensation caused that kind of rust..?
I was pretty sure the salt water coolant had somehow leaked onto the tray to cause that kind of damage.
I better check my tray right away, and will post a picture. (2001 boat)

[Norseman]

Checked my AC, no rust, just a bit dirty, some green algae from sitting fresh water. Noticed a red drain plug that kept all the water in the tray, pulled it immediately.

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No rust on the tray and AC has been used quite a few times as this boat is 100% Florida.

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[Bluewater]

Looks good Norseman. I’m heading out for a day on the Gulf at 04.00 tomorrow but will take a longer/deeper look at my problem on Friday/Saturday. Seems that the issue is abnormal - so I need to identify/fix the cause and then effect the remedial work. Somehow.....

[Norseman]

. so I need to identify/fix the cause and then effect the remedial work. Somehow.....

Well, the kind of deep corrosion you showed on the Initial picture can hardly be caused by fresh water, there has to be saltwater involved.
In my younger days I sailed in the merchant marine on ships made by steel. My job was often to deal with rust caused by salt water, again and again and again...
(Rust expands x 16, if your tray is 2 mm thick, the final result is 32 mm after the expansion)

[RobS]

Yes check for a seawater leak but don't let Norseman's comments put you in a tailspin. For sure a mild steel pan can rust like your from years and years of standing water. Here's one less than 10 years old on a freshwater boat. You can see where the drain was fitted and where the low point and standing water was. There's a reason they eventually switched to stainless or composite pans. How old is your pan?

[Norseman]

. but don't let Norseman's comments put you in a tailspin

Sorry, didn’t mean to be a drama queen
Never seen such damage from fresh water however, but everything is possible, I guess.
Perhaps previous owner had a salt water leak, fixed it but never repaired the damaged tray.

[Bluewater]

Norseman - thank you for the comment - I’ve owned and cruised a couple of steel sailboats and understand what you’re saying.
Rob - I believe that the AC and the pan date from the build in 2000.
In the meantime, I put such cares temporarily behind me and today pretended to clean the hull at a beach inside Boca Grande Pass.......

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[Nancy]

In the meantime, I put such cares temporarily behind me and today pretended to clean the hull at a beach inside Boca Grande Pass.......

Glad to see you have your priorities straight.