Hole in boiler - fix?

Author
Discussion

MellowshipSlinky

Original Poster:

12,060 posts

149 months

Monday 26th October
quotequote all
Have a 5 year old oil Worcester Bosch boiler.
Appears to be a failed weld that holds a bracket for the outer casing to attach to - problem is it’s on the secondary heat exchanger and so leaks slightly.
Currently having a bit of a battle with WB as it’s only a month out of warranty, and in my view such an innocuous weld shouldn’t fail in that time.

It’ll cost around £1600 for a new heat exchanger and labour, which is unacceptable after just 5 years (been zero issues prior to this).

So, first of all I’d like to try a fix - either re weld or apply some sort of metal patty/ patch.
Not sure what to use so just after a few pointers.

Thanks.

(And no lectures about having a Worcester....please... wink )

g7jtk

1,474 posts

114 months

Monday 26th October
quotequote all
Have you tried leak seal

Hoofy

71,250 posts

242 months

Monday 26th October
quotequote all
1 month out? As in you had missed servicing it by 1 month? That's not very impressive quality is it?

MellowshipSlinky

Original Poster:

12,060 posts

149 months

Monday 26th October
quotequote all
Hoofy said:
1 month out? As in you had missed servicing it by 1 month? That's not very impressive quality is it?
It was installed and registered 19/9/2015, serviced every year on the dot except this year my plumber was delayed by that month to service it. ( he came to service it last week)
It’s clear from where it’s leaked that it’s been leaking for more than a month though!

He told me today he installed the exact same boiler 7 years ago and was servicing it today - that boiler hasn’t a mark on it.

MellowshipSlinky

Original Poster:

12,060 posts

149 months

Monday 26th October
quotequote all
g7jtk said:
Have you tried leak seal
Is that something you put in the boiler?
If so no - it needs to be externally fixed.

LimSlip

618 posts

14 months

Monday 26th October
quotequote all
What's the heat exchanger made from, aluminium at a guess? You may be able to use one of the low temperature aluminium brazing rods to make a good repair if so.

MellowshipSlinky

Original Poster:

12,060 posts

149 months

Monday 26th October
quotequote all
I automatically thought it’d be steel - no idea if it’s aluminium or not...



Huskyman

464 posts

87 months

Monday 26th October
quotequote all
Try a magnet if it doesn’t stick it’s aluminium or stainless steel. Chances are it’s high silicon aluminium.

ST12AT

369 posts

127 months

Monday 26th October
quotequote all
The secondary exchanger is covered by a 10 year guarantee, the main heat exchanger is 5 years.

dingg

2,691 posts

179 months

Monday 26th October
quotequote all
If they won't replace or repair try devcon epoxy.
If you can get it dry it'll sort that out.

MellowshipSlinky

Original Poster:

12,060 posts

149 months

Monday 26th October
quotequote all
dingg said:
If they won't replace or repair try devcon epoxy.
If you can get it dry it'll sort that out.
As in this?
https://www.ebay.co.uk/c/1726944893

MellowshipSlinky

Original Poster:

12,060 posts

149 months

Monday 26th October
quotequote all
ST12AT said:
The secondary exchanger is covered by a 10 year guarantee, the main heat exchanger is 5 years.
Not according to Worcester - even though we registered it for the 5 year warranty (due to installing a magnaclean at the same time)
Normally it’s only a two year warranty.

ST12AT

369 posts

127 months

Monday 26th October
quotequote all
Is it a Danesmoor?

MellowshipSlinky

Original Poster:

12,060 posts

149 months

Monday 26th October
quotequote all
Greenstar Heatslave combi.

ST12AT

369 posts

127 months

Monday 26th October
quotequote all
MellowshipSlinky said:
Greenstar Heatslave combi.
10 year manufacturers guarantee covers faulty materials.

Their get out of jail card is very good though so you’ll have a battle....

MellowshipSlinky

Original Poster:

12,060 posts

149 months

Monday 26th October
quotequote all
ST12AT said:
MellowshipSlinky said:
Greenstar Heatslave combi.
10 year manufacturers guarantee covers faulty materials.

Their get out of jail card is very good though so you’ll have a battle....
What’s their get out of jail card in this instance?
Can’t see anywhere re 10 year guarantee.

Faulty weld is where the red dot is - bracket isn’t shown on the diagram.


ST12AT

369 posts

127 months

Monday 26th October
quotequote all
Their list of criteria that needs to have been met to honour the guarantee is rather long.

They’ll test the water to make sure the exact levels of inhibitors are present.

They’ll then do a whole house calculation to see if the boiler was oversized, which it will be because 90% of oil boilers are oversized.

They’ll scrutinise the commission and service paperwork.

amongst other things.

MellowshipSlinky

Original Poster:

12,060 posts

149 months

Monday 26th October
quotequote all
ST12AT said:
Their list of criteria that needs to have been met to honour the guarantee is rather long.

They’ll test the water to make sure the exact levels of inhibitors are present.

They’ll then do a whole house calculation to see if the boiler was oversized, which it will be because 90% of oil boilers are oversized.

They’ll scrutinise the commission and service paperwork.

amongst other things.
To be honest, I’d welcome all that.

I have all servicing paper work, and it’s also all filled in on the boiler log book.
The inhibitor is tested at every service.

The chap that fitted it (included completely new oil lines from the tank, fire loop etc) is probably the most belts and braces engineer I’ve ever met.
He incredibly meticulous on his installs.
Even had OFTEC come down to inspect the install when he’d finished to ensure it was all above board.

Sheepshanks

21,950 posts

79 months

Monday 26th October
quotequote all
That seems a staggeringly crap design - any kind of strain on the bracket could break the weld. That it then leaks is just ridiculous.

You haven't got one of those premium bank accounts with appliance repair, have you?

Legally, you're a bit stuffed as responsibility rests with the installer. Is your guy WB accredited, or whatever their system is called? If he is, it's pretty poor for them to leave him to sort it out.

If all else fails, think I'd be minded to write to consumer help page of the Telegraph or some other similar newspaper. You'd hope WB would respond positively and not want bad publicity, especially if you tie the delay in finding it to Covid.

sparkythecat

7,328 posts

215 months

Monday 26th October
quotequote all
ST12AT said:
Their list of criteria that needs to have been met to honour the guarantee is rather long.

They’ll test the water to make sure the exact levels of inhibitors are present.

They’ll then do a whole house calculation to see if the boiler was oversized, which it will be because 90% of oil boilers are oversized.

They’ll scrutinise the commission and service paperwork.

amongst other things.
What has the size of the boiler is got to do with its longevity?