Skip to main content ↑ ↓
Topic: Aqua Hot Exhaust (Read 1217 times) previous topic - next topic

Aqua Hot Exhaust

I've had a lot of problems with my Aqua Hot since I bought my coach.

Initially the nozzle plugged up which melted the aluminum combustion chamber. I replaced the combustion chamber & did a complete yearly service on the unit which included a new Napa in-line cartridge type filter, as I did not like the existing in-line plastic filter. When I did the service I found that the air intake adjustment was only a quarter of the way open. All instructions indicate it should be 50% open up to 8000 feet. I was having a lot of smoking problems which I could not seem to rectify no matter where I set the intake.

I made an appointment with Roger Berke to have my unit looked at & he pretty well rebuilt the complete unit in Quartsite. Seemed to work alright, but I was on a tight schedule so had to leave within hours of the repairs being completed. The unit kept blowing black smoke to the point I would not park it on concrete as it left such a big black mark. I did alot of research on the Aqua Hot trying to understand how they work, read every post I could find as well as a lot of conversations with Roger. I found nothing on the exhaust. Combustion problems are almost always associated with air flow or poor atomization of the fuel, I knew the internal parts of the Aqua Hot including the nozzle were all new so I felt it had to be an air problem.

My Aqua Hot exhaust pipe has a muffler looking contraption on it. In talking with Roger I indicated I felt I had a restriction in the exhaust & I felt this muffler looking peace could be the culprit. The problem I had was that I am storing the coach outside & in Canada it has been freezing every night up until last week. On the weekend I was able to get the coach into a shop so I cold work on the exhaust system. I completely removed the exhaust system & installed a new 1 3/4" ID exhaust pipe from Aqua Hot to the outside of the coach. My problems have been solved! Instantly on fire up I could tell the unit was running differently. No smoke of any kind & I had a much larger volume of air exiting the pipe as well the exhaust felt much hotter. I have found it takes about half the time to heat up the Aqua Hot than it did before.

I took the muffler & cut it in half to see what it was like on the inside. I found that there is a perforated pipe running through the center of the muffler that was semi collapsed. No matter where you set the intake you will not get good combustion if the air cannot freely flow out through the exhaust system. I will try & include pictures.

I do want to say that Roger is the best & helped me all the way through this process. Anyone that is having combustion problems should check to see if they have one of these mufflers as it may be the culprit.
Lee & John McMorris
1997 36' U320
450 hp M11

Re: Aqua Hot Exhaust

Reply #1 –
More pictures I hope.
Lee & John McMorris
1997 36' U320
450 hp M11

Re: Aqua Hot Exhaust

Reply #2 –
This picture is of the exhaust black mark after one night prior to the Fix.
Lee & John McMorris
1997 36' U320
450 hp M11

Re: Aqua Hot Exhaust

Reply #3 –
Great work!

I was with Gary Omel last week and he showed me his neat 1X2 rectangular exhaust he built on his 2000 42 footer... Very strong with guards to prevent damage from road gators...
The selected media item is not currently available. Dave Head & Megan Westbrook
Titusville, FL - The Great Outdoors
'98 270 buying this month
Toad is a 2018 F150 XLT

Re: Aqua Hot Exhaust

Reply #4 –
Gary also has a lifting tag axel on his 2000.
The selected media item is not currently available.Bill&Doris 97 U270 36'
University of Parris Island Class of 66
Semper Fi  Build# 5174 MC#17094

Re: Aqua Hot Exhaust

Reply #5 –
mcmojo, That is great information for me, my unit works great, but will keep a good eye on the exhaust, thank you for the info.
Dave M

Re: Aqua Hot Exhaust

Reply #6 –
Thanks!  As others have said - good stuff to be aware of :)

Re: Aqua Hot Exhaust

Reply #7 –
Hi mcmojo,
  Did you notice much difference in the outside coach noise with your conversion?

Good luck
LynnD  '01 GV

Re: Aqua Hot Exhaust

Reply #8 –
Quote from: Bill Willett –
Gary also has a lifting tag axel on his 2000.

You forgot to mention that Gary designed and built this lifting tax axle by himself. Gary is nothing short of a mechanical genius and one of the most helpful guys you will ever meet. One of the things I really respect about Gary is that if he doesn't know something, he will tell you so. But that won't happen very often.
George Stoltz.  Retired from full-time living in a great Foretravel and now are back to living in a traditional sticks and bricks in Florida.

Re: Aqua Hot Exhaust

Reply #9 –
Very little difference in the outside noise level. Maybe a bit louder because a lot more air is being exhausted. I think the larger pipe diameter helped keep the sound level down.
Lee & John McMorris
1997 36' U320
450 hp M11

Re: Aqua Hot Exhaust

Reply #10 –
Thanks for sharing, I just noticed a black mark under my exhaust pipe on our last trip. I will start checking it out.
1999 U320
Mount Dora Fl

Re: Aqua Hot Exhaust

Reply #11 –
I recently had a similar problem-black spot, melted swirler, low air flow.  Roger Berke tried blowing the exhaust out without much effect.  I suggested trying water.  I started out with low flow, but ended out blasting the exhaust out at full flow.  We filled the campground pad with black soot particles.  The air flow markedly improved.
Regards,
Brett

'99 42' Foretravel Xtreme
'14 Brown Motorsports Stacker
'05 Chevy SSR
'02 BMW R1150R

Re: Aqua Hot Exhaust

Reply #12 –
Amos, if you have a muffler it may be collapsed & in my opinion your best bet is to get rid of it.  You may flush out some soot but it is only a bandaid measure. The other thing that I have found is that my Aqua Hot would shut down, indicator light would go out at least every second day for no reason. It has now been running steadily since I did the repair on Saturday with out any shut downs. Increasing the size of the exhaust pipe & getting rid of the restrictive muffler are key to the unit breathing the way it should IMHO.
Lee & John McMorris
1997 36' U320
450 hp M11

Re: Aqua Hot Exhaust

Reply #13 –
I didn't even know I had an A-H muffler, but there is was just after the last bend in the exhaust pipe.  I'll replace my exhaust pipe when I get back to Livingston.
Regards,
Brett

'99 42' Foretravel Xtreme
'14 Brown Motorsports Stacker
'05 Chevy SSR
'02 BMW R1150R

Re: Aqua Hot Exhaust

Reply #14 –
We replaced the exhaust pipe last April. Ours rusted off at the output end of the muffler. Per Roger Berke's instructions, I upgraded to 1 3/4" ID & didn't reinstalled the insulation. Much cleaner installation.

- Roger Berke.... Most Aqua-Hot installations do not use muffler.  The only noise you hear is air moving and you have to stand right next to the exhaust pipe to hear it.

Any automotive muffler shop can build a replacement exhaust pipe.  You should upgrade the exhaust to 1 ¾" ID (2"OD) pipe.  That will not only make your Aqua-Hot run better, but will quiet it down quite a bit.

dick


Dick & Sue
'99 U320, 36'
2015 F150 4x4 Supercrew
M & G with brakeaway system
Blue Ox Avail 10,000# tow bar
Grosse Ile, Mi.
 

Re: Aqua Hot Exhaust

Reply #15 –
Is this kinda like putting a set of headers on my old 1970 Pinto?  Just get rid of the muffler completely?