I am fixing an old, pre-2005, MCAL and find that the element that I've been supplied does not seem to fit. Measured across the threads on the mounting posts the old one is 40.9mm and the new one is 45mm. The difference means that the old element sits squarely in the holes in the base of the boiler with the flanges and washers square with the base, and the new one has them at an angle which looks to me like it may not seal properly. The large difference in size and the fact that the new one is a very round number (45) makes me suspect that this is not just a matter of manufacturing tolerances. Is this a known problem with the right parts or have I just been sold the wrong part?

Update: the supplier told me to just bend the element to make it fit and that they supplied thicker o-rings with the gasket set to make it seal. 4mm is a long way to bend something like that. Thoughts?

I suggest bending the element at the spiral. This would keep the legs parallel. 4mm isn't much. Use a vise or vise grips, and go slowly, checking all the while. Good luck.

Thats two advising me to just bend the element, but what kind of manufacturing tolerance is +10% on a 40.9mm dimension (and more than 10% if the size is calculated on the hole or post centers)? I'm appalled.

Greg

Don,
It was Ash who told me to just bend it and he said that he had supplied thicker washers so that it would seal. He doesn't see a problem with bending it that far. I'm wondering whether this is the general experience with these elements or whether something odd is going on with parts supply. Being out by 4.1mm is a huge mismatch for a company whose machines are generally of high quality.

Ash did offer to put it in for me, but I want to understand what is going on before I decide either way on taking the trip across the harbour.

Greg

Don,
The question is whether an element that fits even exists. The answer to that colours the conversation going forward.

My experience with Ash, and before that, with Paul at Mocha Coffee, is apparently better than yours. My experience of the service from both has been very good (although finding out the prices from Mocha Coffee sometimes necessitated a sit-down and a cup of tea).

Greg

On a positive note - although 4mm seems like a lot, seeing as it is cylindrical, it really is only out 2mm on either side from center - bending each side in this much doesn't seems as drastic as bending only one leg in 4mm.

DrDregs wrote:Your experience in getting prices over a cup of tea is telling because no amount of trying to get a cup of coffee out of my machine at the time (not a lever) was in any way successful.

Don,
I didn't mean I talked to them over tea, I meant I had to sit down and have a cup of tea to get over the shock sometimes.

Greg