tag:blogger.com,1999:blog-86698133228747884782024-03-05T04:36:17.968-08:00Alberg 30 sailboat projectThis Blog will chronicle the complete restoration of an Alberg 30 sailboat.Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.comBlogger107125tag:blogger.com,1999:blog-8669813322874788478.post-34621410668301724342012-08-11T14:32:00.002-07:002012-08-29T10:47:43.136-07:00Nesting Dingy<div style="text-align: justify;">
The inflatable dingy we used as a tender was getting a little threadbare and since it had no motor, it severely limited our options for use. An inflatable can be very difficult to row in the trade winds.</div>
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I decided to build a nesting dingy and after a little research online I settled on the Chameleon nesting dinghy designed by <a href="mailto:dtgreene@ibl.bm">Danny Greene</a>. If you would like a set of plans click his name for the link.</div>
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Mr. Greene returned emails promptly and a set of plans arrived within ten days which I thought was very quick considering he lives in Bermuda and I'm in Hawaii!</div>
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I have never built a "stitch & glue" dingy before and thought it would be a fun project.</div>
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This one would be built outdoors, without the comforts of a shop.</div>
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The dingy is 10' 4" overall length, about 4' wide, and is reputed to row and sail well.</div>
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We started the project at the Ala Wai boat harbor.</div>
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My Alberg was in her slip thirty feet from the truck so we had power available while we started the project. The plans were well written and the grid pattern was laid out on the sheets of plywood and we cut out the pieces per the instructions. Many thanks to Jeff, Nick, Wallace & Christine for the extra hands and help cutting, holding, zip-tying, etc. Its a challenge working with light pieces of plywood in twenty knot trade winds!</div>
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Once we had the pieces all cut out we started to assemble it using some utility rope to "spring" it together. We were rookies and it took some trial and error to figure out how best to approach it but before too long it started taking shape.<br />
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We filleted the seams with west systems epoxy and 406 colloidal silica. We loaded it on the tailgate and let the fillets cure overnight.<br />
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The next day we split the halves and cut the tie wraps off and did a little fill & fairing with the dingy placed on the dock box. In hindsight it would have been better to drill the holes for the tie wraps closer to the edges of the plywood so that the fillets would not have to be so wide in order to cover them. </div>
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<br />Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com3tag:blogger.com,1999:blog-8669813322874788478.post-15512215632655420252012-08-06T18:03:00.002-07:002012-08-06T18:03:43.692-07:00Sailing Hawaiian WatersGrowing up on Vancouver Island and learning to sail on small engine-less sailboats at a young age, I developed a healthy respect for mother ocean and her many moods. Eight foot tides and ten knots of current thru the many channels and narrow passages were the norm, often with a heavy fog thrown in for good measure. One quickly learned how to read the tide and current tables and plot vectors and keep tabs on cross track error when underway.<br />
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In Hawaii there are only three foot tides and the currents move along at a mere knot or two.<br />
The weather is for the most part clear and beautiful with a constant trade wind blowing 20-25 kts.<br />
The channels and harbors are clearly marked and well lit.<br />
And with those lovely sailing conditions I was surprised to hear at least one distress call go out on the VHF every day for a boat in trouble! There are several a day for lost persons participating in various water sports but with the huge population of inexperienced tourists visiting the island that's understandable.<br />
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What surprises me is the large number of experienced sailors that get into trouble here. Most have hundreds of hours experience, sailing in more difficult conditions than we have here.<br />
The seas around Hawaii are steep and rough, and I think those steep swells combined with the gusty trades is what leads to most of the problems. <br />
The laid back island style and pleasant weather can lull one into a state of cheerful complacency. Then when sailing out of the harbor all it takes is a jammed halyard and a gust of wind in the channel and you are driven onto the rocks. Its a good idea to have an anchor ready on every approach or departure and have the sails set where you want them before entering the channels.<br />
Though well marked the channels are narrow and they are not the place to be messing around with hoisting or dousing sails.<br />
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I watched this unfortunate sailor get a sail halfway up in the channel, then the engine quit and the sail billowed and they were on the rocks! The large swell beat them hard into the rocks and the skipper had to be carried away on a backboard. By the next day the boat was a loss.<br />
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Many vessels Make mistakes near Diamond head. Misreading the light for another and hitting Diamond Head Reef or turning into Hawaii Kai thinking its something else and hitting the reef as this fellow did.<br />
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Every Friday night they have a big fireworks display on Waikiki Beach and many boats head out to watch them. We were watching the boats return after the display and watched in horror as this boat took the marker on the wrong side and came to ruin on the reef beside the Ala Wai channel.<br />
The hull drifted into the harbor the next day after the surf ripped the keel off.<br />
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So if you plan to sail these waters, don't let the warm weather and laid back island life lull you into complacency when under way. Be ready to 'let go" the anchor when near channels and bays and be sure of your position at night. If you aren't one hundred percent sure you know the channel at night then heave-to until morning and make the approach in daylight. The numerous shore lights can make the approach very confusing at night, even when you've run the channel before.<br />
Its quite disconcerting to be in the channel at night and hear your spotter on the bow who is guiding you towards the next green channel marker say "wait, it just turned yellow! Now its red!"<br />
My butt cheeks clenched tightly together for a moment while we searched for the real channel marker and distinguished it from the numerous traffic lights.<br />
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The Islands are a beautiful place to hang out and I am enjoying my time here.....once moored snugly in a safe harbor. I snapped this sunset shot in Keehi Lagoon with my phone.<br />
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Cheers, Don<br />
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Blogging "island style" _~ _ /)___</div>
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<br />Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com1tag:blogger.com,1999:blog-8669813322874788478.post-48228416110842149542012-03-03T20:53:00.000-08:002012-03-03T20:53:37.271-08:00The complete project in three minutes & forty-one seconds!<div class="separator" style="clear: both; text-align: center;">
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<br />Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com8tag:blogger.com,1999:blog-8669813322874788478.post-2423659566439270682011-12-18T21:21:00.000-08:002011-12-18T21:24:25.424-08:00Old Rivets<div style="text-align: justify;">
I like to walk the deck before every sail and set my eyes on all the pins, buckles, etc.... pull the rigging wires in little circles, testing how much play they have.... make sure shes sound before heading out. As I was inspecting the mast base I set my eyes on the boom and noticed one of the rivets that fastened the boom to the goose neck was tweaked a little sideways. I inspected the rest and was shocked to see that three of the five rivet heads were gone! That left just one intact rivet and the tweaked one holding it together...not good!</div>
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How did I miss this on previous deck-walks! It was a reminder to take my time and be thorough in the inspections. I inspected the other rivets on the boom and the heads looked good but we decided to replace em all to be safe. Jeff and I spent the evening replacing the rivets at both ends of the boom. Even though the aft end looked good I would never trust it without pulling it apart and inspecting it for corrosion etc.</div>
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After that I looked up the mast at the long row of rivets fastening the sail track. I hope I don't have to replace all of those!</div>
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Today I broke out my assender setup and inched myself up the mast a foot at a time on a special rock climbing rope. I wanted to inspect the rest of the rivets and fittings up the mast, if some of the forty year old rivets were bad.....what of the rest?</div>
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I got to the spreaders and immediately spotted some problems. The top rivets securing the port spreader plate had failed and the plate was separating from the mast. the starboard side looked intact but a thin gap that was not there before was evidence they were stretching out and needed replacing.</div>
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I swung around to the sail track and spotted six rivets with heads missing.</div>
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Ok.....a major rivet refit is required before sailing!</div>
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I descended on the grigri to the deck....no sailing tomorrow as planned......sigh.</div>
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If you have a "classic plastic" vessel with old rivets be sure to inspect them before every sail for potential problems. When things go bad under load it can really ruin ones day!</div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com11tag:blogger.com,1999:blog-8669813322874788478.post-52352126014364287902011-11-26T20:05:00.001-08:002011-11-29T19:21:22.981-08:00The Dog House<div style="text-align: justify;">
I was planning to live on the boat in Hawaii but when the Marina heard I had a dog it was clear that Goldie was not welcome. Non-live-aboards are allowed to sleep aboard for three nights a week and they said she was welcome aboard as long as I didn't spend that fourth night....if I did we would both have to go!</div>
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So we had a place to live .....er......visit......for three nights a week. Now what to do for the other four nights of the week? I didn't want to pay the going rate of $1,600 per month for a no frills studio apartment for only four nights a week.</div>
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I looked on Craigslist for a camper to put on the truck and was not surprised to find they don't exist in Hawaii.</div>
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I had never seen one on the road here. Oh sure they have lots of campers listed....but they are what we from the mainland call a "canopy". Here a canopy is a fabric beach shelter.....a camper shell goes on the truck. So I decided I would knock out a cheap, simple camper made of plywood, similar to the one I had on the mainland but without the appliances etc.</div>
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The boat would be used for daily <strike>living</strike>, I mean.....visiting.....not living.......and the camper would be a place to "live" four nights a week. The camper would be a perfect doghouse for Goldie to hang out in when I'm working. Heavily insulated to keep the sun off with plenty of ventilation.</div>
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Jeff asked what the plan was.</div>
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Plan? I said. I plan to build a camper.</div>
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"But how, whats the plan?"</div>
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No plan, gonna wing it, start from the base and add whatever seems to work as it takes shape.</div>
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Ok,... sounds good, he said. With a healthy dose of scepticizm in his tone.</div>
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I thought we'd start with 1/2 inch plywood for the floor and seats and go from there.</div>
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I bought a bunch of 2x2's to use as framing and several sheets of plywood and some glue, screws, etc. I decided on 2x2's for framing to allow 1-1/2" of foam insulation to keep her cool inside.</div>
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The added weight of the wood was no problem as the rig would not have the weight of appliances and water / holding tanks that a regular camper has.</div>
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The base (floor and up to the seats), front, back, and bed platform over the cab, would be built with 1/2 inch plywood. The sides and roof would be thin 5mm plywood.</div>
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Jeff had to work so I drove to a remote beach park & local tent camping place and started the project.</div>
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I built from the floor up to the seats and was pleased with the results.</div>
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Plenty of people came by to have a look and ask what I was building.</div>
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A camper, I replied.</div>
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Ah, oh, I see,...they said, clearing not understanding what a camper was.</div>
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Very few people knew what a camper was or looked like. This was a remote "locals" beach park and few tourists or haole's (what the locals call white folks) made it here.</div>
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After tiring of repeating the explanation over and over I decided to just call it "the doghouse".</div>
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Yup, building a doghouse for her (pointing at Goldie) so she has a place to hang out when we go snorkeling, working, etc.</div>
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"ahhh cool.....lucky dog! most said. As it took shape some added "hey you could use it for camping to you know, would be perfect for it!" I smiled and agreed.</div>
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It started to rain and I drove to the local Home Depot store where they had covered parking and continued to build. We went to the beach park to build when we needed to make dust or paint, and stayed under the covered parking the rest of the time. The staff at Home Depot got to know us well and always had kind works of encouragement as it took shape in their parking lot.</div>
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It was handy to have a fully stocked hardware / lumber store a few steps away.</div>
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Every item we used was bought from them, from wood to tools. If they didn't mind me building it there I certainly didn't mind buying all the supplies from them.</div>
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Jeff helped often, spending his days off and mornings helping me. It would have been very difficult to erect the walls and square up the frame without his help. I am grateful, thanks Jeff!</div>
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A white elastomeric roofing compound was rolled on the roof and their special 4" wide polyester fabric was used over the seams and edges as a solution to the expansion and contraction problems at the joints. It worked well and the white color helps reflect the heat.</div>
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We put in 48 x 12 inch opening double pane windows in the sides. Petty theft is a huge problem here and we kept the windows narrow to reduce the temptation to break them and try and crawl thru. The back of the camper has a narrow sliding door reinforced with steel backing behind the tracks so that it cant be kicked in. A steel plate will be added at the bottom on the outside so it can't be pulled or pried out. Two large barrel bolts fasten the door from inside. Both have locks on them. It would be very difficult to get at the locks and impossible to get cutters or pry-bars on em. It is as secure as I can make it.</div>
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Its a long way from finished but is well under way now. There will be some fill and fairing later when I have access to power at a future date. It was built with hand saws and a cordless drill. Near the end we also used a cordless sawzall which helped speed up the process.</div>
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The start!</div>
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The Floor</div>
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Building at the beach park</div>
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Ships come and go while I build</div>
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Raining, take cover!</div>
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1/2" plywood foundation done</div>
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Painting and walls going up</div>
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Jeff, head shaved for Halloween, he was "Mr Clean"</div>
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Goldie enjoying the temporary Lanai</div>
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Roughing in the forward bunk</div>
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Goldie enjoys the trades blowing through</div>
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Closing it in</div>
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Roof coating applied</div>
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first of many coats of paint</div>
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roughing in the windows</div>
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Windows in</div>
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slide up door</div>
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<br />Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com2tag:blogger.com,1999:blog-8669813322874788478.post-16647336977842779512011-11-20T15:39:00.000-08:002011-11-20T15:39:33.406-08:00Making The Break<div style="text-align: justify;">Well I have finally made the break and moved to Hawaii to live.</div><div style="text-align: justify;">1983 was the first time I came thru here and fell in love with the place and I've been hoping to move here ever since. Twenty-eight years later I've finally done it! </div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">I left Idaho happy to be heading for Hawaii, but with the sadness of leaving loved ones in Idaho. </div><div style="text-align: justify;">Every once in a while we meet someone that goes above-and-beyond and really makes a difference in our lives. In Idaho that person was Gary Dawes.</div><div style="text-align: justify;">I immigrated from Canada and when I got my work visa Gary's company Expert Marine Technology was the first place I applied for a job. He hired me and over the last ten years I had the privilege of working for him. I had never worked for a company that put so much effort into looking after employees. Gary often said his employees were family, and he meant it. </div><div style="text-align: justify;">His rules were easy to follow; "if you make a mistake say so, a person will never be fired for making a mistake no matter how bad it is. No one comes to work intending to break sh**." </div><div style="text-align: justify;">If you asked for a day off you got it, no matter how badly he may need you that day, he always found a way to make it work for his employees. We got a lot of three day weekends when we needed them.</div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">My first month working for him he heard of a sailboat going for a really good price and told me about it. As a new immigrant money was tight, the immigration attorneys had taken it all "helping" us through the process. He bought the boat for me and told me to make payments on it as I could and if I sold it for a profit we'd split the profit. When I finally sold that boat I had made a couple of grand profit and handed him his half. He refused it and told me to put it down on the house we were trying to move into, we had outgrown the apartment we were in.</div><div style="text-align: justify;">We got the house and Gary rented a moving van and he and his son told me to stay outta the way as they moved all our furniture. My boss rented a truck and personally moved my furniture for me!</div><div style="text-align: justify;">Eventually I became the General Manager of his business and was privy to the financial end of things. Our Business is seasonal and in the dead of winter, with the crew laid off for the season, I have seen him give his last hundred bucks to an employee who needed it.</div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">I could go on and on as there was seldom a day that Gary didn't do something above and beyond for somebody.</div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">If it was not for him I would not have this boat, I would not have had the house, the previous boat, etc etc etc. He's a great man and I really miss him.</div><div style="text-align: justify;">Thank you Gary for all you've done.</div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com0tag:blogger.com,1999:blog-8669813322874788478.post-37397034089366923142011-04-11T02:16:00.000-07:002011-04-11T02:16:06.099-07:00Arrived HiloWe arrived at Hilo March 23rd at nine-thirty pm.<br />
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The Seas had been running extremely high and blowing strong for the last ten days with no letting up.<br />
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We got twenty miles from Hilo and it died to light airs then no airs as we neared the bay.<br />
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We go from a triple reefed main (equivalent rolled up) only to full main and genny in less than an hour.<br />
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We had been on only the shortened main for the last three days.<br />
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I had been in Hilo before so entered in the dark, ghosting eerily thru the inky blackness at four knots with no wake in no waves on the inside of the mile long breakwater.<br />
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We sailed right into the gap at Radio bay then dropped sails, and payed out the stern anchor and used a little burst of electric power right at the end to set the anchor and put the bow on the sea-wall. ......we arrived!<br />
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Our neighbors were surprised to see us in the morning.....its fun being electric, we sneak in silently in the darkness.<br />
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The trip was fantastic!<br />
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We sailed off Mexico, between the Coronado islands, beating south with the wind on the nose.<br />
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Ran into a gale day three and four off the Guadeloupe Island and got hammered good in forty plus knots and 18 foot seas (according to the radio).<br />
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Every-time we went on deck we got soaked and hammered in the rain and spray and waves washing the foredeck.<br />
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We had the main down to nothin and the jib up managing kinda a beam / close reach doing a neat climb up the wave and pivot at the top and down the other side with the wind vane steering well thru it even though the waves tried hard to pound her off course often.<br />
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She was quite comfortable and I knew she would do well.<br />
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At some point well into the night the jib blew out.<br />
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I turned west in the morning and headed for the high and more settled weather.<br />
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The winds abated slowly all that day and the next day we found the high and were coasting along at three and four knots in calm seas under sunny skies.<br />
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At night the stars came out and we darkened the boat and sat in the cockpit for some stargazing.<br />
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The stars are amazing at night under the high..,...billions and billions of em! right down to the horizon.<br />
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I took the boat hook and made figure eights in the calm water and it trailed green sparks in the bio-luminescence. It was stunningly beautiful.<br />
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After a few days we turned south to seek the trades.<br />
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We found strong winds from then on and reduced the main to our "triple" reef and left it there for the remainder of the voyage until we reached Hilo.<br />
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After a day we dropped the main and sailed under a poled out Genny for almost the rest of the trip and that was all she needed.<br />
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The odd day that was lighter airs and she dropped to three knots I put up the second Genny I had brought from the salvaged O-day. I sewed the hanks from the destroyed jib onto it and put it on the same fore-stay with the A-30 genny and sailed wing and wing.<br />
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The pole was to light and dipped the water and bent, we splinted it and sailed on.<br />
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Six days out from Hilo it failed in a new place, we retired the pole and used the boom as a reaching pole.<br />
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Five days out from Hilo the wind vane failed, the whole rudder assembly let go. The bottom pin had sheared.<br />
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It had done better than any vane I had ever owned, sigh.<br />
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I hauled the mess aboard and we steered for the last five days.<br />
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Four days out the tiller snapped off with a loud crack as the boat was pushed off course by a very large wave. I hove too for the night so we could sleep.<br />
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In the morning I installed the spare original tiller I had brought along and we sailed on.<br />
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Five days later here we are in Hilo! YAY!!!!!<br />
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We caught five mahi Mahi on the trip and had a great run.<br />
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26 days 15 hours to sail 2,776 nautical mile.<br />
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I spent a week in Hilo resting and repairing.<br />
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My stepson flew down and sailed the boat to Oahu with me in light to moderate airs.<br />
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We had a great show leaving Hilo when several Humpback wales entered the bay and started spy-hopping and slapping the surface with their fins.<br />
The boat is safely moored in Honolulu now in one of the few slips in our marina that was not washed away and destroyed by the tsunami.Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com3tag:blogger.com,1999:blog-8669813322874788478.post-83489548892350617762011-02-24T05:27:00.000-08:002011-02-24T05:27:41.658-08:00Here we goWell the day is finally here! Its five am and we are getting ready to sail for hawaii. Within the hour. Sorry for not including pictures....I am writing this from my droid phone and it will only let me write the blog in HTML mode so its a little tough. <br />
The windvane we made is working well and sea trails went incredibly well, this boat likes to sail!<br />
We have to head south for five or six hundred miles to drop below the high before turning west for hawaii.<br />
We will see how the fishing is off mexico!<br />
Thanks again to you all for the help, advise, and support.....it made the project go so much more smoothly.<br />
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The crew is ready and Kolohe Is tugging gently on her dock lines wanting to be set free .......Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com8tag:blogger.com,1999:blog-8669813322874788478.post-91564117378498402382011-02-16T10:42:00.000-08:002011-02-16T10:43:20.410-08:00Wrapped and rolling<div style="text-align: justify;">The mast was wrapped with thin foam and the rigging secured to it and then wrapped with plastic stretch wrap.</div><div style="text-align: justify;">Then it was loaded atop the boat and the vessel was shrink wrapped for the long haul to San Diego.</div><div style="text-align: justify;">It was an uneventful three day run down to San Diego though she did draw a quite a few looks and she rolled onwards dwarfing the truck. She looked huge shrink wrapped.</div><div style="text-align: justify;">The following day the boatyard lifted her gently off the trailer and lowered her into the water.</div><div style="text-align: justify;">Four years building and she was finally floating! It was an incredible day and an amazing four years!</div><div style="text-align: justify;">There are so many people that helped along the way and I am forever grateful for the help and encouragement to git-er-done! I could not have done it without you all! Thank you thank you thank you!!</div><div style="text-align: justify;"><br />
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</div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com0tag:blogger.com,1999:blog-8669813322874788478.post-14923015360229219542011-02-16T10:02:00.000-08:002011-12-14T15:16:22.244-08:00Dodger<div style="text-align: justify;">
With the launch date drawing near I put the hard dodger project on hold and asked Jerry at Mariners Canvas if he could put together a temporary cover over the companionway hatch.....nothing fancy, just something temporary. He and his assistant Justin came by to have a look and Jerry said he could put something together for me that would make do.</div>
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He suggested a temporary cover would probably be aluminum with plastic fittings to keep the cost down for me.</div>
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They stopped by while I was out fetching parts and put up the frame for it. When I got back I was amazed to see a beautiful frame out of one inch stainless with robust stainless fittings instead of plastic. Jerry smiled "Justin and I got talking about the conditions you may encounter and felt we should use one inch tubing and all stainless fittings. Its such a small dodger we have some offcuts we can use to keep the cost in line"</div>
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I was so damn happy! She was getting a stout dodger after all.</div>
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Jerry said it would be strong enough to sleep on and we tested it by anchoring a hammock to it and it didn't mind it one bit.</div>
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Thank you Jerry and Justin for a job above and beyond what I had asked for!<br />
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12/14/2011<br />
Many folks have emailed and asked how to get in touch with Jerry, here is his contact info;<br />
<b>Jerry Holmes<br />
Mariners Canvas<br />(208) 667-1903<br /> <span rel="vcard:adr">715 E Harrison Ave, <br />Coeur D'Alene, ID
83814</span></b></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJh9WrBQvcyBlqLPtWi_4ZBLdEuD09gYqAHJdv8kYbn6yR36i47A3CF2qo9YjlIc4mSlVgRCvKiH7DT2OLWT8tZRFOZGMb6HcuA-WLtmEBlwHFJoiKdBYe1tOIoEAm1YtOSZxsu-o5lsoX/s1600/2011-01-18_15-36-51_890.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJh9WrBQvcyBlqLPtWi_4ZBLdEuD09gYqAHJdv8kYbn6yR36i47A3CF2qo9YjlIc4mSlVgRCvKiH7DT2OLWT8tZRFOZGMb6HcuA-WLtmEBlwHFJoiKdBYe1tOIoEAm1YtOSZxsu-o5lsoX/s320/2011-01-18_15-36-51_890.jpg" width="320" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidEa6wSogF6xry4p_sxtwdzDMC2oYM-slgSCaGMNVeN709xUXOX5xQo4b-60f8SZkS4s0ESVhVZNPaCseSvERnhPMNqCfovf4yjEFQtvIRShgWSslApQL54ecaf-LL4NNR7gwPlbb8O-V1/s1600/2011-01-18_15-31-41_902.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidEa6wSogF6xry4p_sxtwdzDMC2oYM-slgSCaGMNVeN709xUXOX5xQo4b-60f8SZkS4s0ESVhVZNPaCseSvERnhPMNqCfovf4yjEFQtvIRShgWSslApQL54ecaf-LL4NNR7gwPlbb8O-V1/s320/2011-01-18_15-31-41_902.jpg" width="320" /></a></div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com0tag:blogger.com,1999:blog-8669813322874788478.post-62206136954951670362011-02-16T09:35:00.000-08:002011-02-16T09:35:07.115-08:00motor<div style="text-align: justify;"><span id="goog_1679470228"></span><span id="goog_1679470229"></span><a href="http://www.blogger.com/"></a>For an engine we decided to go electric.</div><div style="text-align: justify;">After doing some homework online we contacted Thunderstruck electric and ordered their brushless electric motor kit for sailboats.</div><div style="text-align: justify;">The folks at thunderstruck were fantastic to deal with. They spent a lot of time explaining the system and what was best for our application. Their after sales service was first class and I was very impressed with this company. </div><div style="text-align: justify;">The installation was very straightforward and went very smoothly.</div><div style="text-align: justify;">Gary fabricated a custom motor mount out of half inch thick aluminum plate and mounted the motor to it at the top and two bearings at the bottom to prevent side loads on the drive-line.</div><div style="text-align: justify;">A two to one gear ratio and idler was used along with a toothed drive belt.</div><div style="text-align: justify;">The motor controller was installed behind the engine on the bulkhead and a drip-less coupler on the propeller shaft completed the installation.<br />
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<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXltBgHPG6MbliapkCTy3GaiYl2tuMcmFRQ4M-ej-TF5jQjPF7SdoSowErGL8sli6zghpb1QkNm21r_wisEt8PKg_wox2rK4s2QxQ0L4OWlGu172k3D083Yl5DMkr5xft1W7CRj5aeFZHO/s1600/motor.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXltBgHPG6MbliapkCTy3GaiYl2tuMcmFRQ4M-ej-TF5jQjPF7SdoSowErGL8sli6zghpb1QkNm21r_wisEt8PKg_wox2rK4s2QxQ0L4OWlGu172k3D083Yl5DMkr5xft1W7CRj5aeFZHO/s320/motor.jpg" width="179" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrITUS7UJofkdVSqImk99xIyq11xH2vmbAdze7utMByOpZtq0Tj1BYzwdBryI-Yepa-N1qVuQQeHRhhPFBMp6VNnax0O9YYTHKgddHNQqJ9z8a26s_vmbR8jos4KtG1eeizNLO4TXlNzG8/s1600/controller.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrITUS7UJofkdVSqImk99xIyq11xH2vmbAdze7utMByOpZtq0Tj1BYzwdBryI-Yepa-N1qVuQQeHRhhPFBMp6VNnax0O9YYTHKgddHNQqJ9z8a26s_vmbR8jos4KtG1eeizNLO4TXlNzG8/s320/controller.jpg" width="320" /></a></div></div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com4tag:blogger.com,1999:blog-8669813322874788478.post-80696751397368415382010-12-22T10:14:00.000-08:002010-12-22T10:14:13.976-08:00Cabinet doors<div style="text-align: justify;">We cut out the face panel for the head's cabinet and set to work on making a door for it.</div><div style="text-align: justify;">A couple of decades ago an ol' shipwright taught me how to build these doors.</div><div style="text-align: justify;">They are easy to make, allow good ventilation, and are surprisingly strong.</div><div class="separator" style="clear: both; text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi15VK6aZcKHZG3bnuDhB0YxYnWfNbjJL-JID2peKwdW1OYVR-2mgH9xvKh_uTd5Pq3_Wlq5AlDETVblFHjlE7rhEFVltLLho5KJXfKuj4SrRDq62kxkX44AucBdx7rUHBAjYJyzCWi7ap/s1600/test+fitting+in+panel.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi15VK6aZcKHZG3bnuDhB0YxYnWfNbjJL-JID2peKwdW1OYVR-2mgH9xvKh_uTd5Pq3_Wlq5AlDETVblFHjlE7rhEFVltLLho5KJXfKuj4SrRDq62kxkX44AucBdx7rUHBAjYJyzCWi7ap/s320/test+fitting+in+panel.jpg" width="320" /></a></div><div style="text-align: justify;"></div><br />
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You can make them any size, I like my frames to be 1.5 inches wide and about 7/8" thick to allow them to be routered down making a rabbet around the edge to inset them into the door frame. This leaves me with a half inch thickness atop the panel face.<br />
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<div class="separator" style="clear: both;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdf6U4qoIM2VpVcZECRcOtK-uuJFxbCS4eTDsMMVUvzxR2IVisTYE20C45vKPeoCrGY2HDhKiBTs6VnXajv1JiqxLPKZwVnjxopjbYGMwmT8vHSVWpBd15V166mwcC2ENvXWPQke0VRLjm/s1600/cutting+groove+in+frame.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdf6U4qoIM2VpVcZECRcOtK-uuJFxbCS4eTDsMMVUvzxR2IVisTYE20C45vKPeoCrGY2HDhKiBTs6VnXajv1JiqxLPKZwVnjxopjbYGMwmT8vHSVWpBd15V166mwcC2ENvXWPQke0VRLjm/s320/cutting+groove+in+frame.jpg" width="320" /></a></div>Once the frames are cut I run them through the saw with the blade set to half an in depth to make the groove for the slats.<br />
<div class="separator" style="clear: both;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCS0_wadAAK-PLMd5VIttWKBZFX14BefhmVNjZ-erTAe5IeDnMFy1fZBBRTtTDfJBcQLhhG_xX7fB7S3pk-K6Kl-JModD6x2Ze9kYIKdc-5BuuzTcUoL0-M7HRRO55BNUXkYTEd8yA3bA8/s1600/cutting+slats+to+length.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCS0_wadAAK-PLMd5VIttWKBZFX14BefhmVNjZ-erTAe5IeDnMFy1fZBBRTtTDfJBcQLhhG_xX7fB7S3pk-K6Kl-JModD6x2Ze9kYIKdc-5BuuzTcUoL0-M7HRRO55BNUXkYTEd8yA3bA8/s320/cutting+slats+to+length.jpg" width="320" /></a></div>We made the slats by ripping boards to the width we wanted then running them through the table saw to get the strips. A thickness planer was used to clean em up and get them all to a uniform thickness.<br />
Then several coats of finish was applied and after they were nice and dry they were cut to length on a chop saw. This is by far the most tedious and time consuming part of the process. I usually spend a day and make a large number of slats at one time and apply the finish and store them in long strips. That way when ever I get the urge to make a door I have plenty of slats on hand and just have to cut them to length and the door can be assembled very quickly.<br />
<div class="separator" style="clear: both;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrx1qEcXKcNwWWPck7MIU9MuChaf6tvirDoU2On-ke6Z0rrqjOlfmMjMDoUkqUJurivK_fdwOcjAbCYl9lEaoZF7PyKCUUWrygkV0Y-xpO9KqqS_0dUCtPZu3qab92Qytj5yhrEoSoivaE/s1600/beveling+slats.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrx1qEcXKcNwWWPck7MIU9MuChaf6tvirDoU2On-ke6Z0rrqjOlfmMjMDoUkqUJurivK_fdwOcjAbCYl9lEaoZF7PyKCUUWrygkV0Y-xpO9KqqS_0dUCtPZu3qab92Qytj5yhrEoSoivaE/s320/beveling+slats.jpg" width="320" /></a></div>I bevel the ends of the slats slightly to make inserting them easier.<br />
<div class="separator" style="clear: both; text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAgJv0v-NvzbpiEltNmZ-ITT6MJZssXwKdUo6a5hhWRwwO17FVt5NRX-tgV80iipM5UwbTg3GJQDiA9AjEzqptl-IHDdFNFkLvsRAGLMESYu3tTYdHTlZ0J-Uqv3ErMd1o9_u_IAXRn57O/s1600/inserting+slats.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAgJv0v-NvzbpiEltNmZ-ITT6MJZssXwKdUo6a5hhWRwwO17FVt5NRX-tgV80iipM5UwbTg3GJQDiA9AjEzqptl-IHDdFNFkLvsRAGLMESYu3tTYdHTlZ0J-Uqv3ErMd1o9_u_IAXRn57O/s320/inserting+slats.jpg" width="320" /></a></div><div style="text-align: justify;"></div><div style="text-align: justify;">For the frame I like to inset the top and bottom rails a half inch into the side rails. this hides the groove for the slats when the door is viewed from the top (or bottom). A screw can be driven into the top and bottom rails from the sides if you like to stiffen it up and covered with a nice wood plug.</div><div style="text-align: justify;">The slats are simply popped into place without glue (none is needed) working from one end to the other.</div><div style="text-align: justify;">When we decide what the length of the door should be we typically divide it by the width of the slats and then adjust the length slightly so that the last slat fits perfectly without trimming the width.</div><div style="text-align: justify;">I forgot to do this on this door so the last slat is a little narrower as a result,...but it will be at the bottom and no one but me will know!.....well .....me, and all of you now..... </div><div class="separator" style="clear: both;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOlULCyqnMnulXrFCUIKiGuiy96VJXXm1QqIe91UzgKlq5w8JH9lCoGyx2JB8g9kY_WlFd03x15YWwQgiYCmBp9GlVKHO4pMN4dIOQSNWhTswDFbXfoy8Y5k9fkdv1fDYcJhLicvLZwWM8/s1600/fitting+last+slat.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="179" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOlULCyqnMnulXrFCUIKiGuiy96VJXXm1QqIe91UzgKlq5w8JH9lCoGyx2JB8g9kY_WlFd03x15YWwQgiYCmBp9GlVKHO4pMN4dIOQSNWhTswDFbXfoy8Y5k9fkdv1fDYcJhLicvLZwWM8/s320/fitting+last+slat.jpg" width="320" /></a></div>Bending in the last slat.<br />
<div class="separator" style="clear: both;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiFPR1hF2FUt6JZZoYNhTDAPgZ4_u25UAOWbS3PiSpo35R5pVUDTRU_Asi5XoKurPZPb502-Gcp2WnQkqacjLDTwRLlIwKD7Q8JaTMhYFSBxU2lzZ3h97HPcn8KNrzmWo66p2JgSsbRR4o/s1600/test+fitting+in+boat.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiFPR1hF2FUt6JZZoYNhTDAPgZ4_u25UAOWbS3PiSpo35R5pVUDTRU_Asi5XoKurPZPb502-Gcp2WnQkqacjLDTwRLlIwKD7Q8JaTMhYFSBxU2lzZ3h97HPcn8KNrzmWo66p2JgSsbRR4o/s320/test+fitting+in+boat.jpg" width="179" /></a></div>Test fitting the door and panel.Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com3tag:blogger.com,1999:blog-8669813322874788478.post-60284930588185956172010-11-24T09:59:00.000-08:002011-11-25T20:56:37.790-08:00Shore power plugs<div style="text-align: justify;">
One of our suppliers passed on this article (picture below) that was published in Latitude 38 magazine.</div>
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I found it interesting and wanted to post it here for others to read.</div>
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As a marine surveyor I often go to a meticulously cared for vessel to perform a survey and find the ends of the <a href="http://www.a1marinesupply.com/index.php?dispatch=products.view&product_id=29781" target="">shore power cord</a> to be badly worn and in need of replacement. It amazes me how something that gets handled every time the vessel leaves the dock can be left to deteriorate to the point where it causes so much resistance that it causes a melt down or in the extreme case in the article, almost kills someone. </div>
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If your plug is worn it would serve you well to replace it. I have seen insurance claims denied for fire damage caused by faulty receptacle plugs, it is often considered a maintenance issue and as such is not covered.</div>
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When unplugging the shore power cord from the vessel turn off the main circuit breaker on the vessels electrical panel before unplugging the vessel. Ideally this should be done on the dockside panel but they are often locked or otherwise inaccessible. When the plug is disconnected while energized it creates little arcs that cause minute pitting on the connectors. The pits fill with carbon deposits that are created when it arcs, the carbon creates resistance that leads to more arcing, more pitting, more carbon, etc. Before to long you have created significant resistance in the connection and are well on the way to a melt down.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUmsYWKD2gJ1IE5AdeFrlUr-hcgxC_X6pGMtUsRhTbKAg28ii3EK_Kcnba_9LdtMztI26oA_bG05OzmJbjVhuXZxCKDv_rK5_ehB8q5EZ9LNfihO7-wnR147LDC4pnbAc4TyF9iZj0cjvM/s1600/Latitude+38+Letters+to+Editor.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUmsYWKD2gJ1IE5AdeFrlUr-hcgxC_X6pGMtUsRhTbKAg28ii3EK_Kcnba_9LdtMztI26oA_bG05OzmJbjVhuXZxCKDv_rK5_ehB8q5EZ9LNfihO7-wnR147LDC4pnbAc4TyF9iZj0cjvM/s320/Latitude+38+Letters+to+Editor.jpg" width="228" /></a></div>
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<br /></div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com0tag:blogger.com,1999:blog-8669813322874788478.post-89912308097438219102010-11-08T21:27:00.000-08:002011-12-05T20:19:52.457-08:00Moving along<div style="text-align: justify;">
Lately the focus has been on finishing up loose ends.</div>
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A wash-down fixture was mounted on the foredeck and tied into the <a href="http://www.a1marinesupply.com/index.php?dispatch=categories.view&category_id=176">water pump</a> for the toilet inlet. The toilet inlet water pump does three jobs now; provides water for the toilet, the <a href="http://www.a1marinesupply.com/index.php?dispatch=products.view&product_id=30109">deck wash-down</a>, and a faucet at the head sink. There is no discharge thru-hulls anywhere near the intake so their is no threat of contaminating the incoming water. The head discharges directly into the holding tank and is pumped overboard from time to time when permitted, or drawn thru a deck suction fitting when required. </div>
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I plumbed a tee into the toilet discharge line and took it up to a deck fitting so that when pumping the holding tank the deck cap can be removed and a water hose used to flush the holding tank.</div>
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A ball valve was placed on the discharge side of the holding tank and a <a href="http://www.a1marinesupply.com/index.php?dispatch=categories.view&category_id=223">macerator pump</a> was plumbed in.</div>
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I got the pump from a customer who wanted a replacement pump as he considered this one to be too noisy.</div>
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I took it apart and cleaned, sanitized, and rebuilt it, put in new check valves and installed it my boat.</div>
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The disassembly and cleaning was a thoroughly disgusting job as there was a significant buildup of foul deposits that needed to be scraped and picked at to remove them from the orifices. Even though I saved a few hundred bucks on the pump I don't think its a task I'd care to repeat!</div>
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A two way valve was installed and the discharge line plumbed into it. From there one side of the valve went up to a deck suction fitting and the other through a vented loop to the overboard discharge thru-hull.</div>
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The last connections were made to the holding tank vent and filter and now the toilet system is finished and operational....although not tested at this time. It feels good to have another system completed and struck from the "to-do" list.</div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com0tag:blogger.com,1999:blog-8669813322874788478.post-20250275663339692792010-10-14T23:15:00.000-07:002010-10-14T23:15:42.702-07:00Wiring<div style="text-align: justify;">We plan on launching the boat this January or February and are at a stage in construction where there is plenty of individual projects left to do. Rather than trying to map out a rigid schedule we typically climb the ladder to the boat and work on whatever job we feel like tackling that night. I find the flexible approach to be more productive for our crew....its all got to be done before she sails so if one feels like cutting and fitting "have at it" ...if electrical is your interest break out the wire! </div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">Speaking of wire, we've been tackling some of that lately. I decided that the led lighting and low current draw items would be easier to run from two <a href="http://www.fisheriessupply.com/productgroupdetail.aspx?cid=5064&keywords=fuse+block">Blue Seas fuse boxes</a> mounted forward rather than running everything back to the panel. I located one of the boxes in the head on the port side and the other in the V-berth hanging locker on the starboard side. The small loads for the port side run into the head fuse box and the starboard side loads run into the hanging locker. The fuse blocks are wired back to independent breakers on the main panel.</div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">So far we have an LED two way light over the galley (shines red or white), a spot reading light for the starboard settee / berth that currently has a G4 bulb that we will swap out for an LED bulb, and a surface mounted LED light in the head that shines, red, white, or blue. The crew calls it our patriotic light.</div><div style="text-align: justify;">A gold plated Cantaloupi light is mounted to the aft cabin wall above the chart table and doubles as a chart light and reading light for the port settee / berth. We installed an LED bulb in it to keep the power demands low. Its remarkable how far LED lighting has come. You can get almost every type of bulb in an LED now. Its great for retrofitting existing lights into low power drawing lights without breaking the bank.</div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">The original plan was to use all gold plated fixtures below decks and stainless on deck thereby reducing the need to polish as the stainless and gold plating doesn't tarnish like brass and bronze.</div><div style="text-align: justify;">We managed to purchase only the one gold plated fixture before reality climbed aboard and we realized we would not have enough "fun tokens" (money) to outfit her all in gold on our budget! It does look awfully nice over the chart table though, the gold sparkling in the light. Perhaps someday we will retrofit the rest......perhaps.</div><div style="text-align: justify;"><br />
</div><div class="separator" style="clear: both; text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNzJhjVoVMoNE5IdhMdDFup0h-Jfqi4mQifSp0ecI1HIRUWh35hXr1ShcB67r-l2GUgIgGh-M2yoksrdNBUwIaKIavi9vQM32S7uS36mkoZ4v_XxrKZdsk6Um7RYeU5agSeTL4j0FM1jKN/s1600/Good.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNzJhjVoVMoNE5IdhMdDFup0h-Jfqi4mQifSp0ecI1HIRUWh35hXr1ShcB67r-l2GUgIgGh-M2yoksrdNBUwIaKIavi9vQM32S7uS36mkoZ4v_XxrKZdsk6Um7RYeU5agSeTL4j0FM1jKN/s320/Good.jpg" width="239" /></a></div><div style="text-align: justify;"><br />
</div><div style="text-align: justify;">We found some self adhesive low profile plastic wire chases at the local Lowes hardware store and used them to run the wires in on the surface of the cabin.</div><div style="text-align: justify;">While at Lowes we spotted a low profile strip of six outlets and bought it and installed it behind the port settee back. It was a bugger to install back there but its a great place for it. The A/C wiring comes out of the panel into a GFI duplex outlet above the shelf on the port side Settee. From there it goes down and into the strip of outlets then carries on through the head and into the V-berth and ends in a duplex outlet. </div><div style="text-align: justify;">The entertainment system will be wired into the strip, things that aren't usually unplugged until they fail, DVD player, Hi def TV, Bose system, etc. Their wires will be hidden and tucked up out of the way.</div><div style="text-align: justify;">The two Duplex outlets will be used for laptop computers, cell phones, etc.</div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com0tag:blogger.com,1999:blog-8669813322874788478.post-70074255568718112112010-10-14T22:06:00.000-07:002010-10-16T16:05:44.011-07:00Installing Deck and Cabin fittingsWe placed the cowl for the chain locker onto the deck and moved it around until we were satisfied with the location. As the chain locker is a self draining watertight compartment there was no need to install a dorade box under the cowl.<br />
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A hole saw was used to cut the hole, starting on deck and cutting through about halfway then finishing the cut from under the deck drilling upwards. Cutting the hole from both sides prevents fragmenting the laminate as often happens when pushing through from one side.<br />
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Once the hole was made the Fein Multimaster was used to remove the core material between the laminate and the void was filled with a mixture of West System Epoxy and colloidal silica.<br />
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Once cured a drum sander was ran around inside the hole to clean up any epoxy spurs and ensure we had a uniform surface. The fitting was then bedded in 3M fast curing 4200.<br />
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The same method was used to cut the hole for the bulkhead compass. The notch at the bottom was cut out using a small flat blade on the Fein Multimaster tool.<br />
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<div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAGiGDovb1T2UaRtxDEs7Ef9hmiOCpUwEAQM55RXk_rE1cW8YxtOU8MabtDAFsGJq1Sk3_RQPW075_QA44JNkTW4z0EWjIEM-rJ7bQQEU5SX-lbPN3ujI2szLoVvvFv_V-h8k7J6zdcPJq/s1600/IMG_20100924_193958.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="239" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAGiGDovb1T2UaRtxDEs7Ef9hmiOCpUwEAQM55RXk_rE1cW8YxtOU8MabtDAFsGJq1Sk3_RQPW075_QA44JNkTW4z0EWjIEM-rJ7bQQEU5SX-lbPN3ujI2szLoVvvFv_V-h8k7J6zdcPJq/s320/IMG_20100924_193958.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;">In response to the comment below and request for information; here is some pictures of the blades we have used in the MultiMaster tool. </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipMhQ9MfpRiZxxkkok4uQQx0f8DwZ5qgThBTLXouwhoi3NCeWEmC2YMDu1smwYgo9qmZtx4vUYgoM6BS1rPLbTBOmvbEx5qA6m5pghBZhjzhs0WtLoCJaxx44Hx0y90_MtRhhyphenhyphendf5dnREC/s1600/recessed.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipMhQ9MfpRiZxxkkok4uQQx0f8DwZ5qgThBTLXouwhoi3NCeWEmC2YMDu1smwYgo9qmZtx4vUYgoM6BS1rPLbTBOmvbEx5qA6m5pghBZhjzhs0WtLoCJaxx44Hx0y90_MtRhhyphenhyphendf5dnREC/s320/recessed.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">The above blade we used to remove core materiel</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgS9zY9kte9sZGrc0ZAIPC1crViL6zhVCcffk4IO6RAhpkbag59Ufj0Sh1mp0nVvtmTmKxSOOW1Lua7DxUAvpQz9WjcB7uArLVrXWYb3cvO6hTaTSBQ92WXOL9PN4M7awbmaF3M2UKclaJ/s1600/Universal+Blade.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgS9zY9kte9sZGrc0ZAIPC1crViL6zhVCcffk4IO6RAhpkbag59Ufj0Sh1mp0nVvtmTmKxSOOW1Lua7DxUAvpQz9WjcB7uArLVrXWYb3cvO6hTaTSBQ92WXOL9PN4M7awbmaF3M2UKclaJ/s320/Universal+Blade.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">The above blade was used to cut the lower portion of the compass hole </div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;"> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhraZ54Rnz8QkE7m9O9ma0ZLiYPAOKEx5oAXjY6FxClDDyNgtwG3Qy_bRfjAE6pjyZRZ-idOY8S9CIUFtfrHszRBTHXYQbbtcUvsd9kruXH1tFqLxhF-URIfslekFiyjnIJWJ-WnIU_MM-L/s1600/flush+cut+bottom.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhraZ54Rnz8QkE7m9O9ma0ZLiYPAOKEx5oAXjY6FxClDDyNgtwG3Qy_bRfjAE6pjyZRZ-idOY8S9CIUFtfrHszRBTHXYQbbtcUvsd9kruXH1tFqLxhF-URIfslekFiyjnIJWJ-WnIU_MM-L/s320/flush+cut+bottom.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;">I really like the above blade with the flat portion. You can keep the flat edge very close to a shelf (for instance) and cut the bulkhead neatly and flush to the shelf.</div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiI9ySp6hqRTvM3W8HEGh8BXX3DmcgTQOcIrJv99a-c0FhZPJc1jOJhnZsxtOV2GucCqiroBeWs9GiFt4BQbpul2VRo4bz9SXsyrCe-D4-BpSD20qCuHKrRGkDgR4aAV9ycrp9Z0M_uvcmy/s1600/scraper+blade.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiI9ySp6hqRTvM3W8HEGh8BXX3DmcgTQOcIrJv99a-c0FhZPJc1jOJhnZsxtOV2GucCqiroBeWs9GiFt4BQbpul2VRo4bz9SXsyrCe-D4-BpSD20qCuHKrRGkDgR4aAV9ycrp9Z0M_uvcmy/s320/scraper+blade.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;">We have found the scraper blade to be very fast at removing stubborn materiel. We used it a lot when re-coring portions of the deck to remove the balsa core and also on the hatches and window frames for removing old hatch gaskets and sealants. </div><br />
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</div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com3tag:blogger.com,1999:blog-8669813322874788478.post-83095976547816204902010-09-16T17:20:00.000-07:002010-09-16T17:20:33.571-07:00The Power of the probe<div style="text-align: justify;">Soon it will be time to hang the rudder back onto the boat.</div><div style="text-align: justify;">Derek used the video scope to examine the rudder tube and ensure we left no voids or pockets that could cause problems later. Its a very useful tool and we can capture images or record video with it.</div><div style="text-align: justify;">It was Derek's first time using the scope and as you can see by the picture he was suitably "wowed" by it.</div><div style="text-align: justify;">The shaft and cutlass bearing is temporarily placed while we design the motor platform. </div><br />
<div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv-oEWOFMpaR1P7hPjiY-PvQcSWFUHfPsZopIp2-rTfBGHiZLNk9brxJOBeS2l480e99f0tcY4F2zxKYgmoyFgWMoqzYHU8ulhbjas-nPC0V6FTO8IxfsQnUbbmO2Tdk33t_nCfHL-Wkme/s1600/P1010031.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv-oEWOFMpaR1P7hPjiY-PvQcSWFUHfPsZopIp2-rTfBGHiZLNk9brxJOBeS2l480e99f0tcY4F2zxKYgmoyFgWMoqzYHU8ulhbjas-nPC0V6FTO8IxfsQnUbbmO2Tdk33t_nCfHL-Wkme/s320/P1010031.JPG" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkIvwYQLcXagCJbsOJzlgjBH4f9VbgptuzIk_zEpvXq-Tsbpk2L9wZERQ3jdjN3lG-8j84egzBI0x6ZTbKqWG8Fke5JuSD6-zIpZ4aOCTev_PKVCgtFC1pVQG-J84sj3jw5s8d3jhe45tL/s1600/P1010032.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkIvwYQLcXagCJbsOJzlgjBH4f9VbgptuzIk_zEpvXq-Tsbpk2L9wZERQ3jdjN3lG-8j84egzBI0x6ZTbKqWG8Fke5JuSD6-zIpZ4aOCTev_PKVCgtFC1pVQG-J84sj3jw5s8d3jhe45tL/s320/P1010032.JPG" /></a></div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com1tag:blogger.com,1999:blog-8669813322874788478.post-28568895237396617312010-09-16T17:03:00.000-07:002010-09-16T17:03:45.446-07:00There be tunes aboard!<div style="text-align: justify;">With the majority of the dust making out of the way we brought the entertainment system aboard to install.</div><div style="text-align: justify;">A Bose stereo system was installed and a nineteen inch Hi definition TV was mounted to the bulkhead on an articulated mount. We still have to tidy up the wiring for it all but its nice to have a high quality sound system playing while we work.</div><div style="text-align: justify;">We thought it only fitting that the first movie to be shown aboard was "Yves Gelinas With Jean-de-Sud Around The World". The crew really enjoyed it and it was (and still is) played over and over while we work.</div><br />
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</i>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com1tag:blogger.com,1999:blog-8669813322874788478.post-12338801186098628322010-09-14T16:55:00.000-07:002010-09-14T16:55:10.667-07:00Hardware<div style="text-align: justify;">Now that all the nonskid is down we've been busy bolting down hardware.</div><div style="text-align: justify;">All the rails and stanchions are in as are the main-sheet traveler and jib and genny tracks.</div><div style="text-align: justify;">We put the fore and aft hatch hinges on the buffer and polished em up and got em installed and the hatches mounted. Both hatches were reinforced with several layers of roving and bi-axial cloth to stiffen them up. Taco neoprene hatch seal was used as a gasket on the hatches and cockpit lockers. Its a hollow "D" that compresses and seals very nicely. </div><div style="text-align: justify;">Gary suggested getting the prop shop to polish the rest of the old hardware, they have a $10,000 polisher they place the props in and it shines em up nice. I liked the idea and sent the rest of the hardware to them for polishing. Should be back in two days and we will see how it looks, the old chrome was peeling and hopefully they will be restored to polished bronze again. </div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com0tag:blogger.com,1999:blog-8669813322874788478.post-41520116152567068122010-09-14T16:35:00.000-07:002010-09-14T16:35:27.988-07:00Cockpit<div style="text-align: justify;">We hope to get her in the water before the big freeze hits and have been plugging away getting as much done as we can.</div><div style="text-align: justify;">We masked off the cockpit and applied Pettit Easy Poxy semigloss "buff" paint. This is the same paint we used on the window frames. We decided it would not look as dirty as quickly as the white would in the cockpit.</div><div style="text-align: justify;">We unmasked the area and let it cure up for a few days then re-masked it and applied KiwiGrip to the nonskid areas. When we unmasked the area we were surprised by how dark the semigloss looks next to the much lighter nonskid, if it didn't come out of the same can as the paint we used on the window frames I'd swear it was an entirely different color!</div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYjGaPT20GT1NE_L2_ODZyaM32Gx-cj1UyYs1nETDpQnJjD6HwoAtQIcs5AEnazmoUdpAsYeidSEFlB0NHATixg2j1G_IoXhF7dMdKPVCvRpJACeGmfOGvnKfIwNypJzZPecHd4gTejFoi/s1600/IMG_20100902_110047.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYjGaPT20GT1NE_L2_ODZyaM32Gx-cj1UyYs1nETDpQnJjD6HwoAtQIcs5AEnazmoUdpAsYeidSEFlB0NHATixg2j1G_IoXhF7dMdKPVCvRpJACeGmfOGvnKfIwNypJzZPecHd4gTejFoi/s320/IMG_20100902_110047.jpg" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgca1egRSkbAVCwLKUFa_VWbMmDtL0LueQHd6BBiM1Y3RTBPWZbgS78elxfmJ6ut3M7TeDxlfutiytYWS4-DfeLXTllPTV_qLrGX121JforL_mnwJDdKQQxIiNuECrMUXD_6DNfI7A7_xvl/s1600/IMG_20100906_185313.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgca1egRSkbAVCwLKUFa_VWbMmDtL0LueQHd6BBiM1Y3RTBPWZbgS78elxfmJ6ut3M7TeDxlfutiytYWS4-DfeLXTllPTV_qLrGX121JforL_mnwJDdKQQxIiNuECrMUXD_6DNfI7A7_xvl/s320/IMG_20100906_185313.jpg" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpj255SIjjpdVIttfTEW0ECYXG-e2RKuWWrxiyVNC-5M_RJKuyZ_4OVm5rI2eJOsDIfD-hiqM4NLTLXcVOk5lgTkNMDA9eEt0z1zOJMGNUNKZqoQ0MojzD9adbJX7lC2SwChZj6UgGQ9ma/s1600/IMG_20100906_223125.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpj255SIjjpdVIttfTEW0ECYXG-e2RKuWWrxiyVNC-5M_RJKuyZ_4OVm5rI2eJOsDIfD-hiqM4NLTLXcVOk5lgTkNMDA9eEt0z1zOJMGNUNKZqoQ0MojzD9adbJX7lC2SwChZj6UgGQ9ma/s320/IMG_20100906_223125.jpg" /></a></div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com6tag:blogger.com,1999:blog-8669813322874788478.post-54943603658989059872010-09-09T17:44:00.000-07:002010-09-09T17:45:01.202-07:00Portlights<div style="text-align: justify;">After Jessie had the window frames picked as clean as possible we brushed on some strong paint stripper to remove the really stubborn deposits. A medium scotch-pad was used with a little water to scour off the last of the sealant after the stripper had gone to work on the frame.</div><div style="text-align: justify;">Jerry from Perception Plastics stopped by to have a look and gave me some tips on making templates for the windows. "don't use corrugated cardboard as it makes a frilly edge that cant be followed precisely when cutting out the material, use poster board or something like it". I had some thin sheets of stiff foam that is used for building radio controlled model aircraft that was a good material for the job so Jared and I set about making templates. </div><div style="text-align: justify;">Once the templates were done and on their way to the fabrication shop we continued getting the frames ready.</div><div style="text-align: justify;">They were sanded to bright metal, wiped with awlprep and primed. Two coats of Pettit semigloss Easy-poxy was sprayed on as a finish. </div><div style="text-align: justify;"> A few days later Jerry delivered the finished, 3/8" thick, acrylic panes for the windows. They were cut out precisely and were a perfect fit. I wanted a light tint to help keep out some of the UV rays and keep the cabin cooler. The acrylic only came in clear or bronze and the bronze was too dark for maintaining good visibility at night so we decided to tint them ourselves. We bought a light tint from the local Napa store, cleared the lunchroom table and got to it. The literature on the box stated that the tint wold block out 50% of the UV rays. That seemed like a happy compromise, a nice light tint that would block half the UV rays but still enable us to have good visibility out the window at night.</div><div style="text-align: justify;">I rough cut the tint to be a little bigger than the window panes while Jared mixed up a batch of soapy water in a spray bottle. We misted the pane with the soapy solution then applied the tint and used a plastic squeegee to chase out air bubbles and smooth it down. The edges were trimmed with a razor blade and the panes set aside to dry. </div><div style="text-align: justify;">Once dry the windows and frames were assembled without sealant to ensure everything was ok. The panes and the adjacent cabin sides were masked off to make cleaning up the caulking a little easier. 3M UV4000 sealant was used for the final assembly as it will not damage the plastic. After assembly we waited about fifteen or twenty minutes for the sealant to start to gel and then used a West Systems plastic mixing stick to remove the excess sealant. The Mixing stick has a fairly sharp edge that removes the sealant easily but wont scratch the acrylic or painted cabin side and the gelled sealant lifts right off without smearing.</div><br />
<div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYyU0-_7CKDFGQ-YDNI8TNjbjVi-hY2Baqm4QZ_GresLviN5whcmRCFmd9gt-7HdfM6stxe-OaKcBMVKaFg-Nz7ITgShAIws8YJRpTh0Jyj6xw3H2tmUvt_zPCsO3NDunHwK3PD_GDYdcv/s1600/IMG_20100811_230259.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYyU0-_7CKDFGQ-YDNI8TNjbjVi-hY2Baqm4QZ_GresLviN5whcmRCFmd9gt-7HdfM6stxe-OaKcBMVKaFg-Nz7ITgShAIws8YJRpTh0Jyj6xw3H2tmUvt_zPCsO3NDunHwK3PD_GDYdcv/s320/IMG_20100811_230259.jpg" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3F8A569g5iy9v4voNhtyuOccXzCu_5kMKw3ivzKZJqp7tT1HFbgD73MelDCYvD9IH9X6NIigX4Wgic600eHrss18p7z4vVRZUI0ixyNC4VsdFUa2_BE-_XhKWF0c1RdopqE2q7PsKQZBt/s1600/IMG_20100815_125636.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3F8A569g5iy9v4voNhtyuOccXzCu_5kMKw3ivzKZJqp7tT1HFbgD73MelDCYvD9IH9X6NIigX4Wgic600eHrss18p7z4vVRZUI0ixyNC4VsdFUa2_BE-_XhKWF0c1RdopqE2q7PsKQZBt/s320/IMG_20100815_125636.jpg" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0v50D0JIc_blVIwDxN0AHct6MjPqRaJdAqsZCSn75Msz5dkaP3Jqgh9Y9ym7aUPT_yYzFBMfDaG6JVd_ZR_A_dtYvZ9g4u7i8NPtwqNiF8Koy45Q1Z7BQSl0kVyy1ftuL1AJmUijwCyLa/s1600/IMG_20100815_093025.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0v50D0JIc_blVIwDxN0AHct6MjPqRaJdAqsZCSn75Msz5dkaP3Jqgh9Y9ym7aUPT_yYzFBMfDaG6JVd_ZR_A_dtYvZ9g4u7i8NPtwqNiF8Koy45Q1Z7BQSl0kVyy1ftuL1AJmUijwCyLa/s320/IMG_20100815_093025.jpg" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIZRmriE_i3fNyA_HCZs0WbIK9uk3ryLqbR_rXS5RuX-4PoBkqzzVjPuowtfbiM-KYudI2rcBiwK6UtjVBslLddeGMtZfmTfQqgZRo2RsHGgqaXnBWhs7GQU55Poft1Q0Ws_Fjmeq1CU1B/s1600/IMG_20100829_113635.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIZRmriE_i3fNyA_HCZs0WbIK9uk3ryLqbR_rXS5RuX-4PoBkqzzVjPuowtfbiM-KYudI2rcBiwK6UtjVBslLddeGMtZfmTfQqgZRo2RsHGgqaXnBWhs7GQU55Poft1Q0Ws_Fjmeq1CU1B/s320/IMG_20100829_113635.jpg" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZGe6yFmoiOPxCqc-PHLYWL4ucHSLJu4CPFcb-Xp-mbkxRmzDTbwUexNsGT93hzIBiLPZMkddeYkTOaKgtwQQBxOvTwfwJNQxbMfdXNOEMIiMAU1FbL4f35OuiR87eEGod-Ps2mY_HYy28/s1600/IMG_20100830_131931.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZGe6yFmoiOPxCqc-PHLYWL4ucHSLJu4CPFcb-Xp-mbkxRmzDTbwUexNsGT93hzIBiLPZMkddeYkTOaKgtwQQBxOvTwfwJNQxbMfdXNOEMIiMAU1FbL4f35OuiR87eEGod-Ps2mY_HYy28/s320/IMG_20100830_131931.jpg" /></a></div>Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com0tag:blogger.com,1999:blog-8669813322874788478.post-39824365330685103652010-09-08T11:49:00.000-07:002012-09-07T23:04:18.362-07:00Kiwigrip nonskid continued<div style="text-align: justify;">
I received many emails asking if Kiwi Grip would cover the tread pattern molded into existing nonskid areas without the need to sand down the existing nonskid. As I had sanded mine down before I discovered KiwiGrip I didn't know if it would cover well or not. I had one piece that still had the original nonskid on it and this weekend I applied Kiwigrip to it and am happy to report it covers well without the need for sanding down the existing nonskid texture. In fact it applied easier and more uniform than the sanded areas, the roller didn't slide at all as it can sometimes do when using a light pressure to finish rolling out the product.</div>
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Donhttp://www.blogger.com/profile/07034740563362780956noreply@blogger.com0tag:blogger.com,1999:blog-8669813322874788478.post-19541829146872970072010-08-31T14:51:00.000-07:002010-08-31T14:54:46.929-07:00Bits and pieces<div style="text-align: justify;">Jessie tackled cleaning all the old sealant off of the window frames. It was a tough job but he stayed with it and got-er-done! Thanks Jessie!</div><div style="text-align: justify;">While he was working on the frames I sanded the old wood coamings from the cockpit.</div><div style="text-align: justify;">It was quite soiled and I wasn't sure how it would turn out. I used the Fess sander / vac combination and started with 40 grit paper and worked up to 320 grit. It came out looking fantastic!</div><div style="text-align: justify;">The Fess sander is a very high quality unit that I inherited from Dennis, a fellow boat-builder and friend who died of cancer last year before he was able to complete his beloved vessel. He was a fine craftsman and was far more skilled than I am at woodworking. His custom built laminated wood hatches, counters, and tables often had beautiful little accents and features built into them that made each one a work of art.</div><div style="text-align: justify;"> He kept a good attitude right to the end and encouraged me to finish my boat.....we aren't getting any younger and when our time here is up.....we're done. We miss ya Dennis.</div><br />
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I quickly learned that the two piece was uncomfortable too sleep on and I much preferred a single bunk cushion. When lying on my back in the bunk the backrest cushion was in the way narrowing the width of the bunk just enough to be very annoying. I used to toss the backrest cushion into the V-berth at bed-time to give a little extra room on the bunk.</div><div style="text-align: justify;">So I decided on this vessel I would keep the bunk cushion as one piece and make the backrest cushion a partial that would leave the lower section open and provide a little more width for sleeping.</div><div style="text-align: justify;">The drawback to a long bunk cushion is it flops around when trying to move it or gain access to the lockers below it. A good way to solve the problem is to mount the cushion to a thin sheet of plywood.</div><div style="text-align: justify;">It makes it far easier to move around and when the cushion is lifted to gain access below, it acts like a locker lid and "hinges" up nicely and takes little effort to hold it there while digging in the locker. </div><div style="text-align: justify;">The bunk cushion was laid on a quarter inch thick sheet of plywood and the outline drawn onto the wood.</div><div style="text-align: justify;">The wood was trimmed a half inch on all sides to allow for the wrapping of the upholstery.</div><div style="text-align: justify;">The foam was then glued to the plywood with contact cement. Half inch thick low density foam with a scrim was rolled out onto the work table and the cushion was inverted onto it so the plywood bottom was now on top.The foam was pulled up over the sides and stapled down to the plywood. It was then carried aboard and test for fit. The fit was good so we rolled out the vinyl and repeated the process.</div><div style="text-align: justify;">The backrest was done in a similar manner but we used two inch medium density foam to start with. We ran the edges through the band-saw with the table set at a forty-five degree angle to give a nice bevel on all sides. Quarter inch foam was glued onto the face of the cushion keeping it back two inches from the sides. This helped form the gentle radius shape. Then the half inch thick foam was laid out and the cushion was finished in the same manner as the bunk cushion. The finished back-rest was secured to the settee with strips of Velcro.</div><div style="text-align: justify;">Jessie and I started in the afternoon and was later joined by Jared and Kyle. Once we got started we wouldn't stop! We all wanted to see the end results before calling it a night.</div><div style="text-align: justify;">As the evening wore on Jared broke away from the production line to whip us up a fantastic meal. Hes an amazing cook and before too long he laid out a feast of tempura yams and zucchini complete with dipping sauce, and chicken katsu served on a bed of rice with a lovely lemongrass, coconut curry sauce over it.</div><div style="text-align: justify;">The feat was impressive considering he did it all on a one burner hotplate and a small deep fryer. </div><div style="text-align: justify;">After the meal we completed the job and installed the cushions. They fit well and everyone had big smiles as we congratulated one another......it was two am, and a major milestone was behind us!</div><div style="text-align: justify;">Thank you guys! Thank you very, very, much! It was a tremendous success and a wonderful evening.</div><div style="text-align: justify;"><br />
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