Photoblog: What’s Up?
Wow, what a busy couple of months!
I've been neglecting the blog, which is something I need to remedy. In my defence, I've been very very busy. So, in lieu of posting the ten or fifteen posts that I should have been posting all along, I'll have to just get the queue out in a very condensed fashion.
Returning to the format of the 'What I Did On My Summer Vacation' series of posts, here's a rapid-fire "clips show" of the last two months.
I started and finished a two-week class in 'Advanced Diesel Engine Maintenance', in which we tore the above Yanmar 2QM marine diesel engine completely apart and put it all back together. I'll probably never take the camshaft out of my Yanmar 3HM, but at least now I'm pretty sure I could if I absolutely had to.
This one warrants a blog post of its own - but then again a lot of these pics do. This is a formal 'Notice To Move' from the Vancouver Port Authority, as delivered by the VPD while I was sitting safely and soundly at anchor just off Kitsilano Beach. The officer explained that everyone was getting these notices as an advance move, so that if the Port Authority decided at any point to tow boats out of the harbour and impound them, they could do so without warning. He also explained that the notices were the result of meetings between the City of Vancouver Parks Board and the Port Authority, over just who's responsibility it was to pay for the cleanup of Kitsilano Beach after anchored sailboats were blown ashore and wrecked in windstorms.
What really bugs me is that since then, talking with other liveaboards here in False Creek, it would seem that this notice was only delivered to abandoned or unattended/derelict vessels left out at the anchorage, and that I was the only liveaboard sailor to receive a notice. Strange, especially since I feel like I've proven myself to be a responsible and conscientious mariner, and I have never been blown ashore.
The notice says that I am anchored without having seeked permission to anchor, but as of now the Harbour Master has still not replied to my email requesting permission to anchor. I really do hope that this notice is the first and last interaction I'll have with the Port Authority, but I can't help feel a bit of foreboding.
In my ongoing quest to simplify and minimize my life, I finally realized that my beloved bicycle just doesn't fit "indoors", and storing the Creamcycle outdoors all winter was slowly killing her. There's room for a bike in the starboard ama if I arrange things very carefully but that's a lot of valuable storage space taken up, especially with the prospect of Miya also having a bike aboard. After much research, I decided that the path forward would be to purchase a Montague Boston folding bike, and migrate all of my pro-grade components from the Creamcycle over onto the Boston frame, and vice versa, and then sell the result on Craigslist. More on this soon.
February 26th 2011 brought the first and last big snowstorm of the season. This pic is a little difficult to make out, but if you look closely you can see the snow drifted up nearly over the cabin window, with a melted/windshaped cutout around the Honda EU2000i generator, wrapped here (as always) in a white tarp to keep the weather out.
March 4th was my 35th birthday, and we celebrated by sailing the TIE Fighter across the Georgia Straight and over to Pender Island for a weekend-long multi-birthday party with twenty or so friends in a mansion on the highest point on the island. Seriously swank - a hot tub on the roof, and 360º view of the Gulf Islands!
Miya took this video at a particularly stressful moment during the journey across the Straight - we'd had lovely 10-15kn winds coming out of English Bay, but as we rounded UBC the winds jumped to 20-25kn and we struggled to reef the mainsail, which wasn't rigged properly for reefing. Shortly after we succeeded, we suddenly lost steering...
The rest of the trip got steadily worse, and by the time we arrived at the west side of the Straight the wind was blowing a steady 30kn with pouring rain and 3m waves occasionally breaking over the decks. We arrived shortly after dark on Friday night, exhausted and happy to be somewhere warm and dry - I don't think my boots dried until Sunday.
We moored the boat at Otter Bay for the weekend while we relaxed at the mansion. This pic shows Dan Ross spraying down the sails with fresh water, after being soaked with seawater. You really shouldn't allow sails to sit with salt on them - the salt attracts moisture from the air so the sails will never really dry out completely, which is really bad for the lifespan of the sails, not to mention the probable cause of the large rust stains visible on the headsail.
I picked up a brand new modern battery charger for a little under half price on Craigslist and installed it, finally taking control over the charging of my batteries! Prior to this I had been charging the batteries directly from a 20a DC-DC converter, which is effective but inefficient, and very very hard on batteries. With the new ProNautic C3 50a charger, my time to fully charge the batteries dropped from seven hours to just under three hours. Take note of the mess of wires in the background - this was taken after I had already pulled two full laundry baskets of unused wiring out of the boat. Apparently at least one of the former owners of the TIE Fighter had rewired the boat, but hadn't bother removing any of the old wiring!
One thing I noticed during the Pender "sea trials" trip was that the winches on the mast had begun slipping. I've owned the boat for over three years now and have never serviced the winches, so maintenance was definitely overdue. I had dropped Miya and DR off at Swartz Bay, and TIE Fighter was now anchored in Sidney, BC, so I had my evenings free to work hard on boat projects. Servicing winches is messy work but quite introspective and satisfying, much like I imagine cleaning a rifle must be. This pic shows three of the mast winches disassembled and my first experiments with using 'Simple Green' to clean the components. Result: 'Simple Green' does not effectively clean winch components.
Being anchored in a new place makes me quickly slip into a comfortable routine. I finally got around to repairing the broken Bodum hand-crank coffee grinder that I purchased last fall, and this pic shows my morning ritual in progress - a pot of steel-cut oatmeal and quinoa on the galley stove, with a Bialetti 'moka pot' of coffee percolating beside it, lit by a sunbeam.
Yet another project that I'd been putting off; the aft cabin furnace needed a day tank. The hard part about diesel furnaces is that they need to be supplied with diesel fuel at about 3psi - this can be achieved with either a small electric fuel pump, or with a gravity feed from a tank stored at least four feet above the fuel intake. The problem is that as far as I can tell, very few companies make a diesel tank with an outlet port at the bottom of the tank! After researching the costs of having one manufactured (about $300), I found this water tank, rated for chemical storage, at the wonderful Sidney Boaters Exchange for a whopping $8.00. Another $6.00 in parts, fittings and tie-downs and I was in business!
Evenings over the next two weeks were slow and quiet, so I got a few chances to move away from the "needs" projects a little and onto the "wants" projects. Here's a pic of the snap shackles on the headsail sheets spliced into the sheets instead of tied in with bowline knots, and the bitter ends of the sheets backspliced. This is not only faaaaaar more attractive, but also much smoother for tacking as there is less to catch on the inner forestay while the headsail slips across.
More detail on the winch servicing project; the acetone in the back proved to be a failure as well. At some point a previous owner had serviced the winches by putting grease on the pawls. Apparently - and this was news to me - putting grease on pawls is a no-no, as the grease tends to thicken and build up, eventually causing the pawls to jam. For reference, you should only ever put oil on winch pawls; grease is fine (and recommended) for the gears, but the pawls only ever get oil.
The thick, gummy grease is difficult to get off of the components, but the ultimate solution turned out to be very simple: diesel fuel dissolves the grease and an old toothbrush cleans off the remainder. The glass and tupperware in the pic above are both full of diesel, stained an ugly greenish-black by the dissolved grease after soaking the components overnight.
While I had the winches apart, I took the opportunity to purchase a 'rebuild kit' from the local marine store, and replaced all of the pawl springs in each winch. In this pic, the silver chicklet-looking chunky steel bits are the pawls, which are held against the gear sprockets by the little flat circular pawl springs, which causes the characteristic clatter of the winch in use. Pawl springs wear out over time, but after cleaning the winches and replacing all the springs, my mast winches now work just like new.
The winch mounts during reassembly, after cleaning with diesel, brushes and paper towel. During this procedure it was so bitterly cold outside that I had to go back into the cabin after cleaning each mount to rub my hands together to regain feeling in my fingertips!
The aft furnace was critical during this period - prior to having the furnace working I was mostly confined to the forward cabin for pretty much everything except cooking, working my day job from either my bed or the "guest nest", which is what Miya has named the port-side single berth.
Upon first lighting of the new furnace, I nearly burned the boat down! It started up just like normal and worked great, but shortly after this photo the furnace began making a "chuffing" noise and the walls of the burn chamber started glowing red hot - I quickly shut it down, but it kept burning for a good five minutes afterwards. Apparently the diesel metering valve had been set for a much more viscous fuel, and when I measured and tuned the meter it was delivering more than three times the normal amount of fuel to the burner. Since the tuning the furnace has worked 100% as expected, keeping the aft cabin warm for days on end.
Speaking of the "guest nest", here is a pic of the newly-painted and newly-shelved cubby below the port side berth, which Miya has named 'the boudoir', and we've decided is her personal storage area while she's living aboard with me. My personal storage space is the opposite cubby, which I have dubbed 'the study'.
In the sail across from Vancouver, we tore the mainsail in no less than five places, mostly due to poor reefing skills but probably the fact that the sail is fifteen years old might have something to do with it. I brought the sails in to Sidney's Leitch and Mcbride sailmakers to have it repaired and to get a quote on a replacement sail. I was impressed with their workmanship and attention to detail, and by the personal service I received - they even picked me and the sails up from the boat, and dropped me off again afterwards.
The biggest project of all, while living at anchor in Sidney, was to gut and replace the entire electrical system of the boat. This meant making final decisions on the organization and placement of the switch panels, and cutting into the walls of the cabin to install them. Here I've discovered that the panel above the stove is only 1/4" plywood, and that I'm able to cut through it quite easily with my pocket knife.
As a part of the electrical system upgrade, I installed LED lighting into all of the under-cockpit cubbies, with the engine compartment getting extra attention as it's probably the one where having good lighting is the most critical. Amazing how much cleaner Maude looks with good lighting!
The forward cabin cubbies - the 'study' and 'boudoir' - shown lit up brightly with the new LED cubby lighting system. What a phenomenal difference it makes, having these formerly dark and dirty spaces now clean, white and bright.
I only have a 400w inverter on the boat currently, but that's more than enough to run things like laptops and cellphone chargers - I really don't have much else to plug in anymore! Still, it's nice to have the convenience of being able to plug things in wherever you are, so I've installed GFCI outlets all over the boat. This one is only temporary - I've replaced it already with a more modern outlet that has a green LED, so that you can tell at a glance whether or not the inverter is turned on.
The galley electrical panel installed and active! I've since also added a backlighting kit to this panel, so the panel labels glow a soft green at night. It's the little touches that really make the work feel professional, and give me great pride in having done it all myself.
I'm very proud of my wiring job - apparently fifteen years of being a network tech has some boat benefits after all! All wires to the switch panels are cut to length and terminate in double-crimped flanged spade connectors on terminator bars, all grounds are bussed together with appropriately-sized wiring, and every subsystem on the boat has an individual circuitbreaker. TIE Fighter now has a modern, well-installed electrical system, onto which I can build with confidence. Next steps: a much larger battery bank, then a powerful solar array and possibly a wind generator. The "grid" just keeps getting further and further behind me.
On yet another trip to the Sidney Boater's Exchange I found a pair of nearly-new horizontally-mounted propane tanks for $100 each. This was a great deal, as used horizontal tanks are very hard to find, and new ones are over $400 each - my propane locker can fit two twenty-pound propane tanks, but they have to be horizontal tanks, standard vertical tanks (like on a barbeque) are too tall for the locker. Packing a propane tank home on my bicycle garnered some strange looks from the locals.
I also picked up a Xantrex LinkLITE battery monitor, which conveniently fit into the hole from the ancient (and dead) Heart Interface battery monitor that was installed on TIE Fighter when I purchased her. Yet another step towards complete mastery of my electrical system - a former boss of mine was fond of saying "that which gets measured, gets managed". This is absolutely true with regards to battery life; I can now measure how much electricity the boat is using at any given moment, and know at a glance how much battery life I have left before I have to run the generator to charge back up again.
After three solid weeks of heads-down work on the boat, a vacation was in order. Miya's close friend and cousin Stacee was getting married in Puerto Rico, and Miya was the maid of honour so I was invited along as her date. We flew to Vieques, a small rustic island about an hour east of San Juan. Vieques is known for beautiful beaches, quiet towns and a large population of unfenced horses running free over the whole island. At times I really felt like I was back living in Costa Rica again, and within the week my spanish came rushing back to me.
At some point, walking from our budget hotel towards the posh resort the wedding was being held in, we were flagged down by pensioners in a small bar by the side of the road, invited in for a drink and to listen to the locals playing music and gabbing. Here Miya has just been serenaded with very decent spanish folk music by the man on the left, and the one-armed man on the right had just finished telling her the story of his being stabbed in the abdomen two nights earlier, on the street a block from our hotel.
We took advantage of the tourist industry on Vieques and signed up for a one-day 'Explore SCUBA' course, which took us out to the end of an unused (but heavily secured) military pier for a pair of dives. The waters under the pier were teeming with life, and I discovered to my great relief that the sinus and inner-ear problems that plagued me as a youth have not in fact followed me into adulthood - I am able to dive after all.
I've included this pic because I think it makes an excellent desktop wallpaper; subtle and not too busy. Click the pic - or for that matter, any of these photos - for a higher-resolution version. We saw many sea turtles, as well as several types of ray and many, many different tropical fish.
Vieques is fairly small at only about seven miles long, but we soon felt the pangs of not having our bicycles. Renting bikes was an option, but at $25/day per bike renting a motor scooter for $50/day seemed like a much better option. In the three days we had the scooter the island was opened up to us in a way that was impossible on foot, and we explored the tiny back roads of the island.
There's something about the sunshine that makes everything a little easier to take... after a few days on the beach it was difficult to remember why we'd been so stressed out about all the little things back home. This pic was taken at the "red beach", on our way back from the "green beach", where we'd discovered that tiny, vicious gnats come out in swarms as the sundown approaches. Miya was strangely unaffected, but bites covered my arms in itchy red welts that lasted for several days.
A month or two ago I visited Miya in Seattle and picked up a 150' length of gorgeous barely-used eight-plait nylon anchor rode at Second Wave, yet another marine consignment store. I think I might be getting addicted to used sailing equipment - this 3/4" nylon rode was a great deal though, at $50 for 150', compared with $1.60/foot locally! I spliced the rope to a 40' length of 5/16" heavy steel chain, and this splice is currently holding me at anchor quite handily.
On April the 6th, I left Tsehum Harbour and headed back towards Vancouver. I missed my tide window for Active Pass that day - with a sailboat you can only traverse the pass at slack tide, and slack tide was at 1pm. I ended up sailing slowly up the Trincomali Channel and spending the night in Montague Harbour, which is a lovely anchorage but in a complete cellular reception black hole, ruling out any extended stay. In the morning I packed up and headed out through Porlier Pass to begin my solo crossing of the Georgia Straight.
The weather for the first days sail was a mix of sun and rain, with long periods of spring-like warmth followed by cold rains and wind. This rainstorm followed me up the channel for several hours, but when it finally caught up with me late in the afternoon it turned out to be an unexpected hailstorm!
The only real downside to sailing in cold weather is the long periods of inactivity, requiring you to basically sit outside in the cold wind for hours on end with nothing to do. Even with proper foul-weather gear, two layers of wool sweaters and wool hats and gloves, it's still freezing. Pair that with the inexplicable lack of a fly on my overall-style foul-weather pants, and the only real movement you have for the vast majority of the journey is the occasional trip indoors to pretty much completely disrobe to pee. Still, apart from the puzzling lack of zipper, I am completely pleased with my Helly Hansen foul weather gear.
Here's a video, taken once everything had calmed down and I was moving steadily forward. After I came through Porlier Pass I was expecting some heavy winds and probably some waves, but the addition of the tidal surges from the pass made for some very, very stressful moments! I got my second reef into the main, but not before stuffing all three bows into the waves several times, strewing tools from one end of the cabin to the other, and spilling the contents of my cupboards all over the floor, breaking a bunch of dishes and making an awful mess. The rest of the trip across was spent with the double-reefed main and staysail, which I finally shook out near UBC. I made an average of about 6kn across the Straight, but once I got the headsail up in more protected waters I reached 9.2kn coming into English Bay.
This is the "new" Creamcycle, built up as a fixie with all the brand-new components from the Montague bike and listed for sale on Craigslist. Do you know anyone looking for a rad (if well-used) bike for the summer?
Yet another class with the Bluewater Cruising Association; this time an outboard motor repair and maintenance class. Here it is Saturday morning at 8am, leaving on my bicycle with the heavy outboard in my backpack.
The outboard, we like to say, "worked really great until it didn't". In Sidney, during a trip to shore, the outboard very suddenly quit with no warning, in the sort of way that makes you think something is very, very wrong. Reading up a bit on the internet, I found out that you're supposed to change the gearbox oil regularly, which I hadn't - though apparently when you go to drain the gearbox oil it's supposed to be oil, not dirty water and metal filings.
Sitting in class, we learned all about the workings of outboards, stripping out sparkplugs and taking apart carburetors, and I slowly dug down into the problem that had caused the outboard to stop so suddenly. Clearly the problem was in the gearbox, but could it be repaired?
When I finally got the gearbox opened up and stripped, a few pieces fell out - and some of those pieces were ball bearings. Well - I use the word "ball" somewhat loosely there; the parts that fell out were anything but spherical. D'oh!
End result? The engine is apparently a write-off. I can probably get a few bucks on Craigslist for it, for parts - but the cost of the replacement bits to get her running again are approximately four times what I paid for the engine originally, and given that it was quite underpowered for the dinghy it was on anyway, I guess I'm now in the market for a good used 8hp motor.
Lastly, I finally added in and plumbed the third 100-liter water tank to the freshwater system. This has been on the bench for a while, but now the freshwater system is pretty much 100% complete - there's still a slow, weeping leak on the galley sink that I need to tend to, causing the water pressure pump to kick in about once an hour to keep the pressure up. As far as I can tell the only fix for that is to replace the whole faucet assembly it hasn't really been high up on my list of priorities.
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Phew! And that brings us pretty much up to current! So many updates, with so little time. I've got to remember to try to spew this stuff out in smaller portions, but when things are moving fast it's really tough to keep up.
Winter Weather
I know that the weather in Vancouver last winter was considered 'mild' by most, but between the steep learning curve of diesel furnaces and a general lack of knowledge regarding boat life in colder climates I can't really say that the experience was particularly pleasant. That being said, nothing last winter prepared me for multiple days of sub-zero temperatures!
Miya and I returned from Oklahoma (she competed in the Route 66 Marathon, finishing in 5:05:24, an excellent time for a first marathon!) on Monday night, but with a -17º windchill we decided that it would probably be best to spend the night at my sister's house. When we returned in the morning, we discovered the cold had actually frozen much of the plumbing solid, destroying the new galley faucet. Fortunately the new hoses held up to the ice and the new flexible water tanks didn't freeze, so we didn't have two hundred liters of water in the bilge to contend with but it was still a nail-biting couple of days waiting for the pipes to thaw. Just to make things interesting, the follow-up to days of bitter cold was a massive (by Vancouver standards anyway) snowfall - Thursday afternoon found me digging out the snow shovel from the depths of the starboard ama and shoveling a solid six inches of snow off the decks. Shortly after I finished, of course, the snowfall turned to sleet and subsequently to rain, cleaning off the remaining snow and leaving me with a pair of dinghies full of icy water to bail out.
The rains haven't really stopped since, but that hasn't stopped us from continuing with boat projects, albeit indoor ones. I've managed (under duress) to get the diesel furnace in the forward cabin working again, a problem that required the routing of diesel fuel lines under the floorboards and rigging an electric transfer pump. Now the forward cabin is toasty and warm, though the new propane stove in the aft cabin is turning out to be not the heat source that the former diesel cookstove was. We've had to run the Honda generator for several hours each day, just to keep a pair of small electric heaters going - it's a disgustingly inefficient way to keep warm, but at least it works. I'm in the market for a second small diesel furnace.
The cold hasn't stopped Miya from continuing to turn Tie Fighter into a home, and now the aft cabin salon has received some Christmas treatment. We even have a small Christmas tree fashioned from a live rosemary plant! The salon doesn't smell like a traditional Christmas, but between the rosemary and Miya's constant baking it definitely smells delicious, a welcome change from the pervasive smell of diesel and the salty sea air.
Steering Trouble and a Windstorm
The weather this past weekend was idyllic, for the season; cold but mostly sunny. No wind meant that the nights in the Kitsilano Anchorage on English Bay were peaceful, with very little rocking save the occasional wake from a passing powerboater. The forecast however called for strong gales on Monday and Tuesday, and we were out of water anyway, so we packed up Tie Fighter and set off to finally return to False Creek.
Miya took the helm, but it was hardly ten minutes before she called out that the wheel was sticking, and that she couldn't turn to the left. I thought it was just sticking, but when I came to try it myself, the wheel was definitely not moving. We quickly threw out an anchor, and I started taking apart the binnacle to see if I could spot the problem. It was immediately obvious when I pulled at one of the steel steering cables; it came up out of the channel easily, and after a few feet of rusty, oily cable came a frayed and broken end!
The ironic part - and I'm quickly learning that the Gods of the Sea are huuuuge fans of irony - was that not even three hours earlier, Miya had been reading my copy of the CYA Basic Cruising Skills manual, from a course I took a couple of years back. Reading the section on emergency equipment, she asked specifically:
"Drew, where do we keep the spare tiller?"
I answered:
"We don't have one, baby. There's no place to attach one, and besides, we have thick steel cables for steering, they shouldn't ever break..."
Now, you'd assume that something as important as steering - especially on a boat with no emergency tiller attachment - would be rigged with stainless steel cables… but if there's one thing the Gods of the Sea like better than irony, it's assumptions. As it turned out, the single exposed section of steering cable was rigged with 3/16ths stainless steel cable, but the rest - the parts impossible to inspect, routed through the walls in rigid conduit - were rigged with regular steel cable. Which, of course, had rusted completely through after a few(?) years of living in a wet conduit.
My good friend Darren was in town on Sunday, on "vacation" from the island paradise in Malaysia where he runs a diving school, and so after a leisurely brunch we tackled the problem of routing the new stainless steering cables. We rented a large, industrial crimping tool and bought a bag of aluminum crimps, then settled in for the nightmare job of trying to thread the new cable into the old conduit. To our surprise and delight, the new cable went through the conduit without a hitch, and replacing the entire steering system (including a stopover to lubricate the turning blocks) took around two hours total.
The interesting part is that I think the steering system is actually the final, single system on the boat that I hadn't actually torn out yet. Every single system aboard has now had my hands in it, either by tearing each system out completely or just removing, cleaning and reinstalling. All of the water lines, all the hoses, the entire electrical system, the bilge pumps, the galley, the head, the lighting, the sailing instruments - everything! Only Maude (the big Yanmar diesel engine) looks more or less exactly like she did when I started, and if you've been reading this blog for a while you know that there's been a serious tonne of work done there as well.
Anyhow. The repairs went fine, and the steering is back to 100% again - even better, in fact, as now the turnbuckles turn a lot easier, and without a frayed steel cable scraping the inside of the conduit the steering wheel turns far smoother than before. We are extremely lucky that the cable snapped while we were only about 300m offshore, still in the Kitsilano Anchorage instead of out in the middle of the Georgia Straight like we were the weekend before - I'm honestly not sure how that would have gone.
For now, we're back in False Creek, and have already survived a November windstorm - though it wasn't even 40kn of wind, we only had out a single 'delta' anchor. The winds came up suddenly, jumping from a gentle 5kn breeze to a 30kn gale in under five minutes, and that was enough to cause us to drag anchor about 200m east, narrowly avoiding slamming into Erik's boat 'Solgangsvind'. We fired up the engine and tried to re-anchor several times, but dragged anchor each time, and on the third time dragging we came a little too close to 'Solgangsvind' again and drifted over Erik's anchor line. I had to quickly tie off our anchor line to a buoy and toss the whole thing overboard, because with his anchor line hooked we couldn't pull our anchor up without also pulling up his, and that would mean multiple boats drifting free in the 30kn winds - it could have been a real mess! With Miya at the helm we motored back west towards the Granville Bridge, searching for better anchor purchase.
We found a good hold just past Monk McQueen's restaurant, deploying a 35lbs CQR anchor and having that hold for an hour or so... but then suddenly the wind picked up again and we found ourselves dragging anchor east towards boats moored at the marina! I had Miya take the helm again, and with a panicked look in her eyes, trying to keep a 39' sailboat off the rocks in the dark with howling winds and driving rains lashing us, she kept the boat steady and pointed into the wind while I pulled up the anchor and attached a second anchor, a 25lbs 'fortress', to the end of the chain. This gave us a 25lbs anchor, 20' of heavy chain, a 35lbs anchor, another 20' of heavy chain and then a hundred feet of thick rope, which - after we set the anchor properly - held us solid for the rest of the night. Of course we still had the GPS anchor drag alarm set all night, but we were never woken up.
Anyhow - we're technically back in False Creek, but the boat is locked up solid while we're away in Oklahoma for the next couple of days so that Miya can run 26.2 miles in the Oklahoma marathon!
What I Did On My Summer Vacation – July Edition
Continuing the saga from my previous posting, I bring you the photo-journal of the second month of my brutal summer adventures in the Shelter Island boatyards. Rather than re-introduce the situation, I'll just jump in...
Canada Day brought intermittant rain, so mostly we just worked under the boat, sanding the overhead panels and getting our feet wet in the ever-growing puddles that pooled inexplicably under the boat instead of draining to the nearby sewer grate.
By the time the rains stopped, the hired boatyard labourer guy had finished grinding off the old bottom paint down to the reddish epoxy barrier coat, before disappearing for a few days - something that would become a recurring theme in the next few weeks. At least the labour was relatively cheap, and honestly the task of grinding off old bottom paint wasn't something that DR and I were interested in tackling ourselves. Bottom paint on sailboats is "anti-fouling", meaning it contains nasty poisons, so that things like mussels and barnacles and seaweed won't be able to grow on the surface of the bottom of the boat.
Let me repeat that for good measure. Many things on worksites are poisonous, but usually the 'poisonous' property is secondary, ie. things like motor oil are lubrications that also happen to be poisonous. Bottom paint is poisonous because that's what it was designed to be: poison. Grinding off old bottom paint throws literally pounds of poisonous dust into the air - no matter how good your respirator mask is, there is no way to make the job any more pleasant!
For the first few weeks, we cleaned up the worksite carefully every night at around 8pm or so, in accordance with the boatyard rules. By the end of July we were pretty much leaving the tools where they fell, and picking up each job the next day right where we left off.
After not showing up for several days (and getting kicked off the worksite following a yelling argument with the boatyard foreman), the hired labourer showed up and finished the job. Finally the bottom grinding was complete, and the bottom was primed with a grey epoxy barrier coat!
July 3rd brought 'Sequential Circus 7', an electronic music concert/party/show that I (with a large group of dedicated friends) throw every six months. Fortunately we've been doing this for years now, and everyone really knows their jobs well... there were no hiccups and the show went off without a hitch. By all accounts, a great party.
In the starboard wing is a special locker for a horizontal propane cylinder. One of the critical points of keeping propane on a boat is ventilation; because a boat is watertight, and because propane is heavier than air, a propane leak can lead to a boat full of propane, silently awaiting a spark. More than a few boats have been blown apart by a bilge full of gas!
The locker must have holes in the bottom of it so that leaked propane can escape - however, some previous owner didn't properly seal up the edges of the holes in the wooden floor of the locker, and as a result they rotted through. What looked to be a couple of small (ie a half-foot square) patches of rot turned into a 3'x4' patch in the hull of the boat.
We found a bit of rot in the bottom of the line locker (a locker for ropes and anchors, in the port wing) as well, so we gutted and replaced a few panels in there. I wish I had a 'before' photo - the angled bit at the far corner of the locker used to be a pair of five-inch holes with an old corrugated steel elbow joining them; a tunnel to provide ventilation between the inside of the forward cabin and the port ama. The kicker: the steel elbow jutted out into the foot of the guest bunk, and would cut your toes if you kicked it wrong! I replaced it with a plywood enclosure and rounded and filletted all the corners, and added a vent grating to the inside of the cabin.
This project took a lot longer than expected - in this photo it looks complete, but it took another week of work afterwards, due to stupidity on my part. I had found a can of paint labelled 'Neutral Base Coat' in the old supplies that came with the original purchase of Tie Fighter, and I had also found a can of white epoxy paint, the same brand. I figured they'd be a good match for the heavy traffic of the line locker, a good base coat followed by a tough layer of epoxy paint. The funny part was that the "neutral base coat" was bright orange! I was a bit run down at that point, so I assumed that they must mean chemically neutral, and so I applied the base coat, waited a day, and then applied the white epoxy coat on top of that.
A week later, the white epoxy paint could still be peeled off with a fingernail, exposing the still-wet orange oil based paint below. I finally figured it out: orange paint is something that multihull sailboats are supposed to carry as a safety precaution... should the boat ever flip over at sea, you are supposed to paint 'HELP' or 'SOS' or something on the hull in orange to assist the rescue. I had used my rescue paint on my line locker, and worse, it was incompatible with my epoxy coat. I had to painstakingly remove all of the white and orange paint, using scrapers and solvents, before being able to paint the locker white again.
The next few weeks were the hottest days of the summer, and any job that didn't require being in direct sunlight was infinitely preferred. We began gutting the salon.
I actually managed to pull Trent away from his insane summer schedule of school, work, and conference preparation. I think this was the only day he took off from his SIGGRAPH submission deadline...
Carrie also made it out several times to help out with the labour - though her biggest contribution by far was the loaning/renting of her Ford Bronco for weeks at a time, without which many of the jobs could simply not have been done. We must have made the trip to Home Depot two dozen times.
This photo shows the bottom of Tie Fighter in her 'dress black'. The grey epoxy barrier coat first received a coat of red antifouling paint, then a coat of black - this way we tell how much of the antifouling has worn off just by the color of the hull.
The propellor, after having years of barnacles polished off with the angle grinder. Two large shaft zincs were later attached. I would have liked to swap out the propellor with a folding one, but we were unable to find one of the appropriate size and pitch within my price range while the boat was out of the water.
This photo shows the newly-repaired bow rail - the brown strip at the top of the hull, basically the edge of the deck. The rail was rotted when I purchased the boat, and was one of the first things I attempted to repair in the summer of 2009. In the year following, I learned so much more about woodworking and fiberglass that I tore out the previous year's repairs and re-fixed the rail... properly this time.
This is the centerboard, tilted up so that the water inside could drain, while the fiberglassed repairs to the leading edge cured. You can see the multiple layers of barrier coat and antifouling paint, as well as the spots where the paint and even the fiberglass had worn completely through, exposing the wood underneath.
Another "tiny patch of rot", at the base of the forward window. We learned pretty early on that it's far simpler to take out an entire panel than it is to try to patch a section at a time. This was probably my favourite repair of the summer - by this point I had gotten the hang of the repairs, and this one went smoothly and very quickly, probably four days from start to finish.
The nasty part is that all of the dust you can see on the right side of the photo is powdered fiberglass. I always wear respiratory protection when working with fiberglass, but there's just no way to keep the dust off of your skin. Taking on a job like replacing this window frame is resigning oneself to at least a week of itching.
Yet another "little patch of rot"... this one has never actually been finished, in fact. I still have to cut the replacement board and fit it into place. One of these afternoons...
The forward window fiberglassed in and partially faired - the next few steps are just adding fairing compound (epoxy thickened with a talc-like filling powder), spreading it out as smoothly as possible, waiting for it to cure, then sanding it down until the repairs completely disappear.
As a symbolic first step towards painting the boat, my signature 'space invader' stickers had to be removed. I have a few more of the stickers, and eventually they'll be re-applied, but for now this was the end of the first chapter in the book of Tie Fighter.
The mast-head instruments never really worked. More specifically the wind speed indicator and the apparent wind indicator were completely smashed; you can see them lying on the ground in this photo. I looked into modern replacements, but a set of modern instruments can easily run well over $2000! I tracked down the company that made my instruments on the internet, and though they no longer make sailing instruments, they still had replacement parts in stock. A set of replacement masthead instruments ran me about $350. I also took this opportunity to replace the masthead 'tricolor' light with a combination tricolor and anchoring light.
The largest and most scary repair was the centerboard trunk - we had found signs of rot in the trunk walls, the sides of the housing for the centerboard. This section is often referred to as the "backbone" of the Searunner trimaran, and rot in here would eventually destroy the boat completely. I left this job for last, so that I would gain experience from all the other repairs and do the best job possible. The first step to fixing the centerboard trunk would of course be to remove the sections of the cockpit floor that had also shown signs of rot and would need to be replaced, and to gain access to the top of the trunk itself.
The new cockpit floor would be exactly like the old cockpit floor - 3/8" marine-grade plywood, soaked in epoxy thinned with acetone and fiberglassed. This would be a very high-traffic area, completely exposed to the elements for many years to come, so we took our time to make sure that the replacement boards would done perfectly.
While I worked on the cockpit, I had DR painting the inside of the port ama. This was very possibly the harshest job of the summer, and DR was slightly more suited to the task than I, having a somewhat leaner frame than I as well as significantly more painting experience. I did not envy him the task, but he did a really great job on it.
In mid-July I had another friend come on nearly full-time to help with the boat; my friend James began staying at the boatyard with DR and I, and he proved to be a hard worker. Here he is scraping Sikaflex 291 out of the window frames... Sikaflex is a marine adhesive and sealant that stands up to pretty much anything. There's a saying in the boating world: "That which Sikaflex and the Lord hath brought together, let no man tear asunder!". Foul, foul stuff, nearly impossible to remove!
The biggest part of any boat repair job is the removal of the old materials - at some point we discovered the new Dremel 'Multi-Max' tool, which proved to be a magic wand for these sorts of repairs. In this photo you can see three of the four sections of cockpit floor removed; the fourth didn't show any signs of rot, so we left it in place.
Also in this photo you can see the beginnings of the centerboard repairs! To my huge relief, the rot in the centerboard trunk was not very extensive, and we were able to cut out the rotted parts, soak the non-rotted exposed wood with propylene glycol to kill any remaining rot bacteria, soak it all in acetone to dry it out, brace the boards with fresh, sealed marine-grade plywood, and then finally fill the resulting gaps with epoxy thickened with powdered adhesive. I am confident that the repairs are stronger than the original construction.
Dan Ross completed the painting of the port ama, but with another upcoming heat wave staring us in the face, we decided that it would be better to have the boatyard labourer do the other ama.
The cockpit floors went in smoothly, and sanding would soon begin!
With a heatwave under way however we took any opportunity we could to work 'indoors' or underneath the boat... anything to stay out of the hot sun! The days were so hot that by noon we wouldn't be able to think straight, and after a few near-misses involving power tools we decided that it would be best to try to take it a little easier during the hottest parts of the day.
The former mast step had been completely destroyed by rot, so I manufactured a new one by laminating four layers of marine plywood together with epoxy and then fiberglassing the whole thing over. I do not expect to ever have to replace this part again!
While the mast was down I decided that it would be wise to replace all of the internal wiring as well, and so over the span of two days I dragged over 250 feet of new wiring through the length of the mast, using tarred sailing twine given to me by my friend Kym Rich. This photo shows the knot used to secure the thick coaxial cable prior to dragging it through - if the knot were to let go, getting the cable through would have been a nightmare! This knot was subsequently covered in duct tape, and the system worked perfectly.
I had many visits from friends and family during this month. I tried to take photos each time, but I often failed and/or forgot. Here is my friend Emerson Tan and my baby sister Jen - five months pregnant in this photo - helping to remove chainplates.
The centerboard continued to be a project, one that could often be worked on during hot periods of the days, and so many hours of grinding and patching later it was nearly complete. This photo shows the board cleaned and shining in the sun.
Prior to painting, all of the former anti-skid paint had to be removed. Anti-skid is paint that has a rough texture - often it's as simple as adding regular beach sand to the paint, but in the case of my boat it was a little more uniform. Sanding the anti-skid proved to be incredibly time consuming, and using the angle grinder was delicate work that often caused scarring of the fiberglass underneath. In a stroke of luck, we discovered that methyl-ethyl-ketone (MEK) solvent dissolved the antiskid paint, and after flailing for days with sanders and grinders, Chad Taylor and I took off all the antiskid in an afternoon with solvent and hand scrapers.
This photo shows the stripped wings, ready for priming and painting. Or at least we thought so, but as it turned out we had many days of sanding left before we could paint...
The hatches on Tie Fighter stand up about two inches off the deck, which is more than enough to catch on a wave coming over the decks. A big enough wave could tear a hatch open, which could end pretty badly under rough conditions, and so each hatch has a pair of wedge-shaped blocks of teak to deflect those incoming waves. I had gone to one of the boatyard shops looking to purchase a little block of teak for the top of the binnacle, and they offered to do all of my brightwork for not much more! The block of teak I purchased - the square piece at the top of the photo - was $40 finished, but to have them refinish all of my teak was only another $20, so I jumped at the chance.
Another "tiny spot of rot" was at the top of a very important bulkhead in the forward cabin, where the stay for the staysail attached. The former attachment hadn't been sealed well, and a leak had been patched over from the inside... which means that the leak itself wasn't repaired, just masked. A large chunk of the bulkhead had to be removed, and the repairs had to be *strong* - this four-inch thick laminated plywood brace was the final answer.
The crossbrace was carefully sized and finally bolted into place with another twelve 1/4" bolts and lots of thickened epoxy. This marked the end of the rot repair projects!
Now that the repairs were pretty much complete, the next stage began in ernest - sanding and fairing every square inch of the boat, in preparation for painting. The sheer magnitude of this task was staggering - painting a large sailboat is a huge task, but painting a large trimaran is three times as much work!
Around this time, my friend Jesse came out to start helping with the boat repairs as well. Jesse brought his experience working at an automotive body shop to the table, and his attention to detail made a huge difference in the final project. At this point, each day I expected the boat to be finished "within a week", and each week I realized that it would be at least another week of hard labour before we'd be even close to finished.
The end of July found us still hard at it; I was beginning to lose my confidence, and my wallet was significantly lighter than I had expected it to be at this point, but I was still confident that the end was nearing and that I'd yet have a great summer sailing adventure. At the very least, I'd have a few hot summer nights sitting at anchor in English Bay surrounded by friends, making music on the water, right...? Little did I know there would still be another solid month of work before the boat would even be back in the water, and another two months after that before she would sail away under her own power...














































































































