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2nd Thursday in the yard

Another busy day.

Before getting out of bed I updated our main website (www.aboarddignity.com) removing the references to hybrid as that we no longer are. Probably once we’re up in Fiji and we’ve had some time on the new engines I intend to write a retrospective on our experience on the hybrid system and a comparison to the new.

I spent some time reading the manuals for the new sail drives and motors. I now have a good idea of servicing requirements now. There will be oil changes every 250 hours with an extra one thrown in at 50. I will have to reread and check I have all the things I need to do these jobs.

The big event of the day was the installation of the diesel motors. The crane arrived on time and the motors were lifted into the lockers in turn. There were millimetres to spare as there were guided in by Bertrand with Joel down in the locker settling them onto their bed. To get the starboard engine in I had to move one of the wind gen supports. I tided this high up to the starboard bimini support. Once the engine was in we have to reverse the work. All went well.

Looking at the weather forecast for the weekend we see 50 km/h winds forecast for our launch on Saturday. That’s a no no. Shouldn’t set off with new motors in a gale. After some discussion with the yard they’re going to try and squeeze us in today. The techs say they’ll be ready. We have a busy day ahead.

We applied two coats of primer to the sail drives morning/afternoon. We’ll try and get two coats of anti-foul on today but it will go in wet. Probably going to have to do a lot of scraping down there over the next couple of years.

I inspected the SSB ground plane and found that the corrosion was largely superficial and decided to leave it in place. Later in the day the work was finished under our bunk. The spare parts from the hybrid system went under the bunk, drawers replaced and all the stuff from under our bunk went back – all creating a lot of space in the boat. Our nest in the cabin was dismantled and our bed moved downstairs to it’s rightful place.

Derek and Alison from Kalida have agreed to take our life raft down to Auckland where it will be serviced. So that was removed and taken to their boat. I made up and printed out a map for them to find the place.

Helen and I spent a while checking the forward port locker for leaks as we know water was getting in. We knew the bridle point was letting in water so we fixed that first. We confirmed that the hatch was letting in water where the support meets the hatch so that was also fixed.

In all this we found time for Helen to wash down the foredeck and me to fix her computer cable.

As implied above the techs made very good progress yesterday. By end of day we were clearing up the rubbish under the boat. The scrap metal guy came and took away our spare motor. We subsequently learned the second motor is not going to be sent to Oz so we need that picked up too.

We’ve been left with all the purchased tools and left over parts. I had thought of buying some spare hose clamps but now have loads of them as well as many assorted bolts, nuts, washers, cable ties, etc. that weren’t needed.

Busy and exciting day ahead of us today. It’s not certain we’ll go in but the yard will try their best. One large cat goes in early then they’re hauling a monohull which has a hole in it’s side. Then in we go. If all went well earlier and we have time. Fingers crossed. Otherwise it’s Sunday.

At the end of the day it was really nice getting into our own bunk. It felt like we’d finally arrived home.

2nd Wednesday in the yard

In the morning I reordered Sam’s PC. Perhaps someone was sabotaging our Dell order but in the end it gave us a breather to rethink things. As this is to help Sam improve his skills with graphic design while aboard and hopefully lead to work in that field we felt that given that the industry is so biased towards Apple we should go that way. An arm and a leg later, his laptop was ordered. That wasn’t the end of it as Apple divied up the order into lots of separate credit card charges which blew the security. A couple of Skype calls later we were sorted.

I’ve more or less finished the nav station work. The last few pieces I needed arrived in the marine store allowing me to wire up the two hand held GPS cables. These, along with the USB cable to the SSB and a serial cable all pass through a gromit that I’ve now placed around a newly drilled hole in the nav station. Previously these wires tucked around the side of the old nav station creating a bit of a mess. With all this done I can now use the rotary switch to select between four sources of GPS information: The main chart plotter, the new AIS unit and the two portable GPS units. The signals from whichever source is selected go to the two radios so our position will be communicated if we use the distress signal. The rotary switch also affects which source feeds the serial cable so I can receive GPS data into the computer from multiple sources. With the portable units stored in the microwave this gives us a lot of navigational redundancy.

I have left the placement of the GPS antenna attached to the AIS unit for a later date. It seems to work well inside but I want to see how this works over time.

Helen applied another coat of primer to the new patches on our underside and then finished helping to clear out the old sealant around the forward windows. The worker finished the job off by cleaning off the surfaces and apply new sealant. Hopefully no new inside wine spills will make their way outside.

Also finished by the yard workers is the polishing of the hulls and the gelcoat work where I removed the old AIS antenna.

After lunch I went into town with the French techs to buy starter batteries and anti-freeze. I did a lousy job of translating – at one point translating something one of the techs said in English into bad French.

Of minor note I had one propane tank filled and picked up a replacement connector for Helen’s laptop. It isn’t quite the right size but it may work. I’ve also contacted an alternate scrap yard to collect the unwanted motor. The first lot didn’t show and have been out of contact since Monday.

The sex change is flying along. The sail drives are now installed and a lot of the wiring put in. The throttles are in place at the helm. Today the new motors go in. The techs reckon they may be finished by Friday morning. They’ve agreed to change their schedule around a little allowing us to have our berth back this evening. Helen will be most happy as will I. Living in the salon with all our tools around us is losing it’s charm. This does mean that today I will have to push forward my planned work to redo the SSB ground plane which got a bit corroded from our shaft seal leaks.

2nd Tuesday in the yard

Welding has been done. Spent a fair bit of time disconnecting the solar panels and bimini lighting cable and drawing them up the inside of the pole they run down leaving a sacrificial cable in their place. Didn’t want them damaged by the welding. Once the welding was done I had to reverse the process. It’s a bloody awkward place to work in the boat but helped by the fact the motors are not yet installed. The place where we had the visible crack was drilled before welding to prevent the crack from spreading. All good for our peace of mind.

Helen had a very busy day. We have four patches under the boat now where the old shafts came out and the supports used to be. They’ve all been filled and glassed over. Helen applied the first coat of primer to these four patches. She spent the rest of the day helping to remove the caulking around the forward windows. A very time consuming job.

I fired up the soldering iron and replaced the rechargeable batteries in the autopilot remote. When that was all done I reconnected and tested. Things seemed ok for a couple of minutes then the autopilot alarm went off saying the autopilot was off line. As everything has been touched we all had a bit of a panic tracing the problem as it could be anywhere. It turned out the wire that connects to the autopilot remote had some damage and was shorting everything. Fortunately I had a spare Sea-Talk (propriety Raymarine network) cable and was able to make up a replacement.

With my soldering iron I also tried to fix the connector for Helen’s laptop charger. Turned out I really need a new connector so that’s now on the things to find in Whangarei list.

The rest of the day I spent on the back of the new nav station panel beginning the wiring of the various GPS cables/devices into the rotary switch so that I can switch between sources into my serial cable and the two radios for their distress beacons. Unfortunately some of the parts ordered the previous day to finish this work hadn’t arrived so this is still not over. More ominously a simple test between the chart plotter and VHF radio failed to register a GPS signal. It wasn’t a good test so the way I did it may have been the problem. I now rather regret not writing down all the wiring connections I’d deduced the first time I did all this. Oh well. Lesson learned.

Oh – and the SSB control head and speaker are now both glued on and connected up.

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.