T
tamz
Ive taken the cylinder out and its currently in the garage awaiting my attention. I will certainly try running a screwdriver around the threads but, having had a quick look earlier, I noticed that the second thread in from the outside of the cylinder seems to be slightly flattened so maybe thats causing the problem ! If I can get the new element in square would that cut another edge or am I being too optimistic ?
That is indeed what is causing the problem. It can be fixed. The good thing on your side is that copper threads are quite soft (that is why you stripped it in the first place) so can be fixed. It just needs a wee bit time and care taken.
Forget the 2 1/2" nipple idea. The thread is 2 1/4" BSP. You will struggle severely to get an iron taper nipple that size (2 1/4"). This is an unusual thread size not used on many other things. A thread file is no use as they are for external threads.
There are a couple of ways you can fix this. Basically you have to fix the bad (flattened) bit on the thread so the element will pass it and continue in the other threads. Once it passes the bad bit it will be fine.
Start by scraping the cylinder threads completely clean then follow the threads with a small flat bladed screwdriver or the edge of a small triangular file. If you have a dremmel you could use that. You need to take out the flattened bit.
Keep trying the immersion by hand. If you cant get it in by hand past the couple of turns where it jambed remove it and scrape the threads again. If you take your time and spend 20 minutes or so at it. You should be able to fix it.
If you really can't then it is plan B and how much you value your time against talking the customer into a new £300 odd cylinder!
Buy one of these.
Essex 2.25" E2/SX Immersion Heater Boss Flange CURVED surface cylinder tank e2/r | eBay (Btw the photo shows the washers on the wrong way round)
To fit this you need to cut off the old immersion boss and fit the flange in its place.
They are easy to fit. The hole doesn't need to be perfectly round. You can drill it out and file it if need be.
Plan C is fly me down to do it for you but you would be cheaper with a new cylinder :lol:
Just go for it.