Hole in boiler - fix?

[MellowshipSlinky]

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... )

[MellowshipSlinky]

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]

g7jtk said:

Have you tried leak seal

Is that something you put in the boiler?
If so no - it needs to be externally fixed.

[MellowshipSlinky]

I automatically thought it’d be steel - no idea if it’s aluminium or not...

[MellowshipSlinky]

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]

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.

[MellowshipSlinky]

Greenstar Heatslave combi.

[MellowshipSlinky]

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.

[MellowshipSlinky]

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.

[MellowshipSlinky]

Our last Worcester boiler (a very large inefficient floor standing one) was well over 25 years old before we changed it.