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2nd Monday in the yard

It’s already been a week here in New Zealand. Time really flies. Apart from the first couple of days the weather has been pretty good. We’ve slowly adjusted to the new time zone and for the last 2-3 days have been waking with the dawn. That gives us a couple of hours to ourselves before the techs arrive.

We continue to keep ourselves busy.

Helen spent several hours yesterday repairing the front trampolines. They really need replacement but with repairs we think we can keep them going another year or so. She also applied anti rust to the light fittings around the boat to keep them nice and shiny.

I managed to whittle down the list of things to do a little further.

With the techs now confident of a Saturday launch I called the town basin marina to arrange a berth there. We’ll know exactly where we’ll go on Friday so we’ll need to pay them a visit to see where.

I did some additional testing on the AIS setup. This time I read the manual. I confirmed my suspicion that while stationary out position is only communicated infrequently, every three minutes in fact. So with the antenna splitter still in place I went back to the boat where we first tested so see if we were visible. After waiting five minutes we didn’t show. Bummer. I managed to find another boat, Oceans Dream, who also had an AIS receiver. Turned out they could see us. So I know we’re transmitting which makes me feel a bit better. It could be that the first boats antenna is low down and with mine up the mast, our proximity could be an issue. Something to discuss when I see them again.

I spoke to Peter to arrange a few bits of work on the boat. I’d removed our old AIS receiving antenna and needed the holes gelcoated. We also discovered the other day (by Helen flinging some wine over her shoulder) that the caulking around our front windows is degrading and there are gaps where fluids (red wine) can penetrate/escape. So we want that replaced. We also want our new props coated with prop speed before we launch. Finally we wanted to arrange a visit by a metallurgist to look at our bimini supports and the pictures of the tests we made.

When the metallurgist visited he agreed the forward supports were ok. He also said the back supports would be strengthened with some welding but that could be done in situ. So we’ve arranged for that to be done, more for peace of mind than anything. The bigger crack we knew about since August has not grown so it could be quite old and developing very slowly. However, now we know they are there it’s best to get it sorted. The main hastle with doing this is that the starboard support has wiring running up it which will need to be raised while the welding is being performed.

I updated the software on the main chart plotter. This is reported as fixing a really irritating bug that was introduced a few releases ago whereby the screen would sometimes rotate when set to show our course pointing upwards. I prefer this view but can’t stand the rotation so have not been using it for sometime. I’m looking forward to seeing this working properly.

The hybrid system had a circuit box where there were a whole bunch of breakers and relays controlling where the mains power was delivered. The box itself is a different configuration to that of the 220V boats. The chap who is buying our parts off us was therefore not interested in the box. However, the individual parts are common so I spent some time dismantling the box so we could include the individual parts.

On a trip out I visited the local scrap metal folks. They offered me $1.20 a kilo for the old battery cables. That’s a fraction of what they’re worth so I didn’t sell them. I may end up doing so but that is a last resort. They offered me $1 per kilo for the electric motor. We’re looking at sending one to Australia by freight. The second is scrap so at least we’ll get something for that. They should be over this morning to pick it up.

While out I spent some time running around town picking up various bits an pieces needed for additional projects. I also bought a new can of contact cleaner as I used up all my old cleaner last year on Fijian TVs and DVD players. I also bought myself a decent crimping tool. Using the cheapo one that I have has created a nasty burst blister on my little finger and it doesn’t really do effective crimps. So in more ways than one spending a bit of money on a decent tool was worth it.

Back on the boat I set about fixing the cable that I’d previously cut that joins the AIS transponder to the switch on our new navigation panel that allows us to disable transmission as well as sending a distress signal. I’d had to cut the wire to get it through a small hole. It also turned out to be too short so I needed to add an additional segment. As it was a six strand wire with a shield I needed to crimp 14 connectors. I was really happy I’d bought the new tool.

From my regular check list I managed to find time to test our EPIRB. The test is supposed to be performed within 5 minutes after each hour. A couple of times I was waiting for the hour to be reached and got distracted. The third time I sat there with the EPIRB in my hand so I wouldn’t forget.

Joel and Bertrand continue to march onwards with the conversion work. They’ve cut a lot of holes in the boat now for exhausts and for the sail drives to poke through. They’ve run a lot of wires around the boat and installed the engine gauges / controls. They’ve also painted the interior of the engine compartments so they’re looking all clean and new. They’re targeting installation of the engines for Thursday so the crane is now booked.

Sunday in the yard

We had very little breeze in the morning so we were able to complete the stainless steel testing. The results for the forward port support were also encouraging. Having tested the key areas we now need to run the pictures by a metallurgist for their expert opinion.

I managed to find someone in the yard who had an AIS receiver and was able to test the system. We first tested with the AIS splitter in place and didn’t see anything. I hindsight this might have been due to us not waiting long enough so this will need to be retested. After leaving the other boats AIS receiver on, going back to our boat, connecting the AIS transceiver directly to the antenna and returning to the other boat I could see Dignity loud and clear. I also managed to confirm that the boat length was indeed programmed incorrectly. In the end this turned out to be very easy to fix. While the configuration software stated it could not be reprogrammed twice, the message was referring only to the MMSID (radio license id). I can change the dimensions and ships name as much as I like.

It’s worth noting that I’m definitely getting better range/reception out of this new set up. I can see boats at the mouth of the river which we never could with our old antenna.

The rest of the day was spent finishing off the nav station. It took more time than I had imagined but I got there in the end. You can see the before and after pictures in the slideshow at the end of this blog.

Although it looks finished there are still a few things left to do. The SSB control head and speaker are loose and probably need to be glued on. In the past panel the speaker was jammed in but the current hole is just the right size so I can’t do that. Because the control head is nearer the edge I can’t use the old method I used to fix it. Hence I may have to glue them on. I also have to create a hole to run the USB cable from the SSB modem. I’ll also pass the wires for our portable GPS through this hole as will pass the RS232 connector that will allow my PC to receive information from the various GPSs. I then need to connect all this up via the rotary selector switch and connect these all to the SSB and VHF radio so each unit will receive GPS signals again. In doing all this I also need to connect the new AIS to the chart plotter.

Ok. So I haven’t finished the nav station but it looks it and I feel happy with the result.

Bertrand and Joel came for the morning. They spent quite a lot of time on the rear rail which covers the join between the top half of the boat and the bottom. Turns out the weight of the dinghy and the movement at sea have pulled the parts apart. They fixed all this and did a fantastic job of it. The pics below show the separated parts (after all the current glue had been removed). Need to get one of the finished result as it looks good. I need to hunt around for what else they did. It’s hard to keep track at times.

In the evening there was a bit of a get together at the communal area to hear about some recent adventures of a mixture of Fijians and westerners who took to the sea in a group of vessels based upon traditional Fijian designs. It was quite interesting but a great excuse to get everyone together. Dave and Suzie from Sidewinder were there as were Derek and Alison from Kalida. We met a few other folks from here in the yard who we hope to see again over time.

Saturday in the yard

In the morning we managed to test one of the forward bimini supports where it attaches to the roof. This is where we know another boat had a failure. As far as we can tell this test came out well. It was quite hard doing the test as we had to protect all the underside of the bimini and boat surface below as well as use a tarpaulin to protect the area from the wind. By the time we finished this support the wind really kicked up so we passed on the second.

The rest of the morning was spent marking out the new piece of wood for the nav station with the positions of all the kit being installed on it. Then came the scary part of cutting it all. At this time Malcolm, who we got to know last time we were here in NZ, popped by to say hello. He ended up helping by holding the wood steady while I cut the holes with the jigsaw.

We broke for lunch and went into town to eat by the marina. There we met past (and probably future) crewman Paul and his son Tom. We feasted and chatted and were all very grateful when Malcolm insisted on picking up the bill.

We all returned to the yard to see how things were getting on. We hung out in the communal kitchen for a while drinking coffee and chatting some more. By the time Paul, Tom and Malcolm headed off it was nearly 4pm.

I checked out the holes I’d cut in the morning and found one to be too small with the others being almost perfect. A little more sawing and that was done.

So that’s about it. Our slacking off in the afternoon means less was done that we could have but we deserved it and feel no guilt.

In the meantime, the French techs are making blinding progress. The engine beds are now fiberglassed in and some of the electronics installed. They are making enough progress that they can do a half day today and go sightseeing this afternoon.

Friday in the yard

So Dell didn’t get back to me. It seemed my original order had been deleted out of existence. I could find orders I made a year ago but not the one from yesterday. So I ordered another laptop for Sam. In doing so I noticed I put the wrong expiry date on my credit card. So I corrected that and crossed my fingers. I woke this morning to find that order has gone the same way. I don’t think Dell wants me as a customer. Now time to consider options (and kind offers).

In the morning we had the nice treat of a Skype video call to see our granddaughter Bao. She was asleep which is how she always is when we’ve seen her. I’m not complaining because this is far better than crying. Crying babies is something from my past. Coped with it then. Had enough of it now. Still – it’s good to be able to use the technology to stay in touch.

Helen and I took a trip out in the car to get some bits and pieces. After trying a number of different stores in town I found a place who could make up a longer VHF cable to join our VHF radio to the new splitter and a cable to join the new stereo to the splitter so we can use the mast antenna for radio. I left my order and returned to the boat.

We then set about testing the stainless steel at the base of the two rear bimini supports. This process highlighted the crack we knew about on the port support and revealed two more on the welds on the starboard support. What we really need to do is to test the smaller supports on the forward end of the bimini but they’re in an awkward spot and we really need to have a still air day. We do know of a Lagoon 420 that had a forward support fail so this is driving us to assess the risks on our boat. The next thing will be to decide what to do about what we find. If we have to do work it would be better here in NZ. It’s good to know we have a potential problem than we can get ahead of but part of me feels ignorance would truly have been bliss. For a while at least.

The French techs worked furiously. The hybrid system is no more. While they worked I collected the pieces I wanted to keep and arranged all the parts we’re selling to another hybrid owner. The motors were winched out of the overhead hatches using the main halyard and lowered to the yard. Trying to lift one of them I couldn’t even budge it. I decided I didn’t want to take them to Australia to sell them. There is no way we can reasonably store them. And the additional weight is something else. I let my contact know of my decision. One last option is to freight one of them over. I have to look into the pricing on this. I can’t imagine it will be cheap.

As they progressed we had occasional conversations with the techs about differences they were finding.  The main complication was the addition of the inverter/charger. Their English is as limited as my French so it took time to work things out. Diagrams and google translate were both very useful. In the end we worked it all out.

By the end of they day they had not only gutted the hybrid system (RIP) but made inroads into preparing the rear compartments for the installation of the motors. I felt for Joel who spent a couple of hours sanding away the interior of each space to prepare the surfaces for bonding on the motor supports.

It was amazing how much wiring and cabling was ripped out of the boat. I collected a whole load of 12V wires that I can keep for future projects. I’ve left a whole load for folks here in the yard to help themselves to. I collected up all the 70mm2 and 50mm2 72V cables for the propulsion system and took them into town to sell them. Unfortunately the guy who runs the used boat parts store wasn’t interest so we’ll need to come up with a plan B.

While out I picked up the VHF cables I’d ordered earlier. Back on the boat I installed them. The stereo radio reception is now far better than we’ve ever had. Great.

Throughout the day Helen spent a lot of time clearing out the port bow locker. It had collected a lot of water. We’d fixed all the leaks a year ago. The anchor bridle came loose just before we left Fiji so we know that’s a possible ingress. But the amount of water in there was too much for this. It’s quite likely the hatch is leaking. So sorting out those leaks is now on the project list.

I also performed a few of my regular inspections. I checked all the shackles and the cable ties preventing them coming undone. I also checked the sail cars for any damage or loose screws. All was fine. I also struck a few items off my check list – all those to do with the hybrid system. No doubt, a few more items will be going on to do with the propulsion.

I had a few email exchanges throughout the day with the folks who sold me the AIS unit. Having first defensively claimed the unit was programmed correctly they then went on to ask about cabling, baud rates, etc. Kind of daft when it’s clear the boat name and station id are all coming through ok but the boat dimensions are coming through consistently wrong. I went along with their emails as we have to work out what the problem is. Either the unit was programmed incorrectly or the software is failing to read the dimensions or it’s something else. I should be able to read my own boat dimensions from the unit so something’s up. The best test will be to get someone to receive my AIS transmission and tell me what they see. Going to have to find someone to help.

We finished the day sharing a beer with the French and stretching our overlapping vocabulary. It again strikes me how poor the approach to teaching French was at school. At the end of the day it’s all about being able to communicate. Our collective conversation was grammatically horrendous and a total jumble of language. But we understood each other and that’s what mattered. They are both quite nice guys.

Thursday in the yard

First thing after waking up was to look at the power supply / video problems for the new stereo. I didn’t want to lose any length on the wire so I had a tedious time picking away at the crimps with my wire cutters so I could release the wires intact. Once apart I tested an alternated idea with the positive wires to switch the unit on and off via an external switch. That idea worked but for the time being I left the wires simply twisted together. I then installed a relay which would ground the brake switch detector after the unit was switched on. That worked too. Now the unit will play videos and show pictures. Not essential functions but may as well have them.

Next I had a trial run with the dye penetrant. It’s a three stage process. First the stainless steel has to be cleaned. Then the dye has to be sprayed on and left for 10 minutes. After cleaning it off, a developer is sprayed on to draw the dye out of any cracks. When I sprayed the dye it went everywhere including all over the gelcoat nearby. So it ended up being a rapid clean up job. I got my lessons learned. Next time we need no wind and lots of protection for the nearby surfaces. As the weather was deteriorating rapidly, I postponed the rest of this work.

Through this time, Helen started cutting out paper templates for all the items that will be going onto the new nav station. This was to allow us to move them around and design an ideal layout. Helen did a good job of this and ended up with a pretty good solution I think. I dread cutting out all the holes as one mistake will require a restart. Don’t fancy that.

We’d promised Sam a new laptop while in the Uk and while chatting with him online we found a good candidate via the Dell refurb site – something we’ve used a couple of times before and have been very happy with the results. Being refurbs one has to pick from what’s available without customization and what’s available can change over time so if you see something you like, it’s worth ordering. So I did. Another item off the list. Or so I thought. This morning I found an email from Dell saying the order had been cancelled and not saying why. When I check on line there is no trace of the order. I called the customer support who couldn’t help. They put me onto someone else, who also couldn’t help. They put me through to sales to sort this out. Turned out this was accessories sales. At this point I was a bit pissed off and explained they were the third person I’d spoken to and I felt I was getting the run around. They promised to have someone call me back. We’ll see.

The French technicians, Joel and Bertrand, showed up in the morning. They had a walk through of the boat to check things out. They then needed to buy tools so I went as passenger taking them to the local Bunnings (big DIY store) to get the tools they needed. On the way back we popped into a marine store then we talked to the yard manager, Peter, to understand services available from the yard. Despite the late start the techs are still targeting a launch on Saturday, March 3rd. They’re going to be busy.

The next job for me was to fit the AIS transponder and antenna splitter. It took a while to decide where to put them but in the end I decided on behind the lounge seats where we currently have a fuse box. This meant moving the fuse box too. The fuse box used to have all six connections used up for various items at the nav station. Because I’ve now gone for fused switches on the nav station the fuse box behind the lounge seats now will only have a couple of connections – one going to the nav station switches. So it doesn’t matter if it’s a little out of the way.

In the end I got everything in and accessible. I needed a power source for the two AIS components and decided to wire up the new switches panel prior to installing on the as to be cut out panel (which Helen has been designing). That meant hooking up the inverter to the panel, the new radio (finishing that job off) and the two new components.

Next was testing. I first tried the AIS transponder on it’s own, connecting it to the VHF antenna without the splitter in the circuit. Using the provided s/w and connecting it to my PC I was able to detect one boat up in the Town Basin Marina. So I know it’s receiving which is good. But I don’t have a read on sensitivity as I don’t know how many boats I could/should be seeing. One disappointment was that on checking the configuration, I discovered the supplier has got the boat length wrong and the boat width set to zero. The configuration s/w says the unit can only be configured once so I’ve sent an email to the supplier asking for suggestions.

Next I tried the transponder in line with the splitter. That worked too. I then hooked up the VHF radio to the splitter and tried a radio check while the AIS was running. That came through loud and clear too. So all the vital functions are good. An annoyance with the boat spec to sort out. And I need to buy a longer cable to join the splitter to the VHF radio as the one we have isn’t quite long enough. Pity. I also need to get a cable that will join the splitter to the new stereo so we can also use the mast antenna to listen to the radio. I think Helen is getting fed up with my playlist.

By now it was getting close to 5pm so it was time to tidy up the immense amount of mess I’d created. As I reached the end of the tidying we cracked open a beer each to celebrate a good days work. At this point we were greeted by knocks on the boat. Dave and Elana had found us. We were due to meet in town but they’d decided it might be fun to scour the local boatyards and find us first. As it was now passable inside we invited them in to sit around on toolboxes and the like. We subsequently went out for a Thai meal in town and then went for a walk along the waterfront. It was nice to catch up with them, find out what they’ve been up to in the last three years and to share some of our experiences.

We were quite pooped when we returned to the boat. We did well avoiding opening a bottle of wine, our usual habit. Perhaps this is the first sign of our progress towards Helen’s target of four bottles per week.

I did get a response from the email that NZ Garmin Customer Support gave me. Turns out it’s for returns. I’m pretty sure I’m not still under warranty so this is a dead end.