Tag Archives: norsand boatyard

Why Aren’t the Beers Cold?

Lots of good things happening in this blog post. We leave Norsand Boatyard and finally splash in the water! We stay at Port Nikau for a few days while we discover why our beers aren’t staying cold and we do a big provisioning run.

Splashing at Norsand

We splash back into the water after what seemed like a lifetime on the hard.  In reality it was 3.5 months of living in dirt, dust, and chaos.  

It was time to ensure our boat was water tight after installing (3) new thru-hulls below the water line. It is always frightening making new holes in the bottom of the boat – but Matt did a great job and we had no issues at all!

As you know, we have keel coolers for our fridge and freezer.  Because of this set up we were not able to run our fridge or freezer while we were on the hard.  

We bought a small 3′ refrigerator for $100NZD and kept it in the cockpit.  It kept our drinks, beers, and butter cold.  

Since we were not cooking on the boat we did not need much in the fridge.  

Now that we are back in the water we have to test the refrigeration systems and see what needs some attention.

Kevin and Shane did an excellent job putting our home back in the water.  

Port Nikau Marina

We did not go far once we splashed.  We headed a few miles down the river to Port Nikau Marina.

Normally, we would not go straight from the yard to a marina, but we had some work on our refrigeration.

This two-year old marina is new to us.  It is fairly small with two piers holding about 48 yachts.  They also have a superyacht and commercial dock on either side of the private yacht piers.

The marina is run by Blaire who is absolutely wonderful!  He met us on the dock to catch our lines and gave us the details of this pretty marina.

One morning we had an absolutely beautiful sunrise.

Matt had discovered that our main fridge was not keeping his beers cold.  So, we planned to stay at Port Nikau Marina for a few days to figure out why.

We hired Big Fridge to do a quick maintenance and add freon to the fridge.

Keeping the Beers Cold

Oh no, back to tearing up the boat?  Seriously.  Luckily it was only a one day mess, 

Big Fridge came and did a basic check of our refrigeration systems.  We quickly determined that one of our connectors had a leak. Big Fridge changed four gaskets and stopped the leak.

Matt used a special wand to test for other leaks and it was going bonkers. 

Matt tore up the bead and followed the lines to our keel cooler.  The wand went crazy again. 

I was  horrified as this meant the keel cooler had to be replaced.  The only way to replace the keel cooler is to haul out again!  Oh no.

We decided to let it all sit for a few hours and went back with the wand.  This time the wand was quiet as can be.  We topped up the freon and watched the temperature drop!  It is working!

We let the fridge cool down to our standard – 4 to 6 over the next 36 hours. 

When we realized it was working normal we did a provision run.

Final Touches Before We Go

We did a quick trip to Auckland (6 hours return) to visit Costco.  Loaded up on essentials. Another trip to two grocery stores for fresh produce and few more stops.

I sold our cockpit fridge to one of the workers at Norsand.

Next, I sold our beloved Audi A6 Quatro. 

We have really enjoyed this zippy car!  But it was time for someone else to enjoy her. I sold her for what we put into her. We bought it for $5,500 NZD and had a major service done which cost $600NZD. So, she sold for $6,100 NZD ($3600 USD).  Yep, can you believe that?

Now we are off to explore New Zealand’s coast!

Our blog posts run 4-6 weeks behind actual live events.

We were in Port Nikau toward the end of February 2026.

Managing the Maintenance Part I

Being on the “hard” at the Norsand Boatyard offers us the opportunity to do a lot of maintenance in addition to the upgrades and repairs.  We have a long list of “to do” items that are perfect to tackle while laid up.

Here is a list of the items we worked on that are mentioned in this blog post:

  • Paint Cross Beam and Martingale
  • Saildrives and Prop Repair Maintenance
  • Rudder Arm 
  • Varnishing
  • See Part II for additional maintenance

Paint Crossbeam and Martingale

The crossbeam is at the front of the boat between the port and starboard hull.  It is an integral part of our boat structure and rigging.

We painted the crossbeam and martingale twelve years ago and the paint was showing its age. 

It is a huge process to remove the cross beam.  We removed the lifelines, dropped the anchor chain, removed the anchor roller and nav lights, secured the mast, removed the forestay and furler, and removed the front part of the trampoline.

Removing the Crossbeam

We had problems removing the the crossbeam. 

Each side of the beam has one bolt that holds the end of the beam to a bracket that is then bolted to the boat.

We thought it would be easier to remove the single bolt on each side rather than removing  the bracket which has 4 bolts.  However, we were wrong.  The two bolts were stuck and had to be cut out.

New plan.  Replace the bolts, drill the holes to make them circular again, and fabricate brass bushings to remove the play.

The crossbeam had its corrosion areas ground out, filled, sanded, primed, sanded, primed, sanded top coat.  

We brought in Rob from RH Precision and his “Adjustable Hand Reamers” to drill out the holes, and to fabricate new bushings.  See bottom left photo (gold colored bushings).

This will make the cross beam much sturdier and easier to remove in the future.

Installation

A one week job took 2.5 weeks.  It was finally time to get the crossbeam and brackets on the boat.  

First we install the bolt bushings on both sides.

Next we install the 1 main bolts that holds the crossbeam to the bracket.  

We then return to the boat to install the other bracket onto the boat.  Of course, tough gel and lots of sika flex were used on everything.

Aaron, the yard manager drove the fork lift expertly allowing for a smooth installation.  No scratches, bumps or bruises on us or the crossbeam.

The result is beautiful

Saildrives & Props

We hired Whangarei Marine Services to do some general maintenance on our saildrives.  They replaced the seals (near the props), changed the gear oil, and cleaned our props. 

We also hired RH Precision to do some work on our props. 

Sugar Shack has 2 props and one spare hub.  One of the hub’s inner splines were really worn down causing some issues.  So, we decided to clean our spare hub and use it instead. 

The problem with the spare hub was that it had some dezincification (it is pinkish) which means it won’t last but 3-4 years. 

That works for us as we plan to repower and replace both the hubs and props before then.

One more thing.  Matt had noticed that the props had a little movement from the axel.  

Rob created a bushing to go around the axel to make it more snug and eliminated some of the play.

Rob made sleeves for the axel which greatly removed the “play.”

By the way, we are replacing all zincs so ignore the shotty ones in the photos below.

Rudder Arm

Do you remember when our port rudder arm (which controls steerage) broke at the access point?  If not, please read “Failures Bring on Frustrating Times“. 

We were able to weld it back together but we always considered that a temporary fix.

We took the rudder arm to our good friend Rob at RH Precision to properly fix it.  Rob crafted a new piece which is twice (if not more) as strong as the original piece. 

Not going to fail us now.  Left piece is new and right piece is old in the photo below.

We evaluated starboard’s rudder arm and it looked solid and strong.

Varnishing

I took a stab at varnishing for the first time two years ago.  See blog post “Varnish, Varnish, Varnish.” It looked amazing for about 1 year.

I could not remove some of the teak pieces off the boat, so they had to be varnished in place.

However, other pieces were easily removed so I could work on them in the shade of the boat.

For some strange reason, the pieces of teak that were removed did not hold up as well as the pieces left in place. 

The pieces left in place are fine whereas the ones that were removed all need to be redone.

We learned that it was possible that some of the pieces failed because water “sat” on them. 

The princess seats had water between the teak and the stainless and the swim steps are in/out of the water a lot.  Hmmm, might be a possibility.

We decided to have Norsand revarnish with Awlwood. The teak is really old (25 years) and really should be replaced.  But we really want to wait until we get to Indonesia to replace all of the teak.

Be sure to read about our brand new solar arch – it is super sexy!

Our blog posts run 8-10 weeks behind actual live events.

We finally remove the funky taste and smell from our potable water tanks. See the blog post on the entire process.

We were in the Norsand boat yard working on repairs and maintenance items from November 2025 to January 2026.

Impactful Upgrades

New Zealand means great friends, beautiful country, delicious food, amazing activities, and lots of boat work.  This third trip is no different – did a lot of little upgrades and lot of big upgrades that will have a huge impact to our daily lives.

This blog post will focus on the “little but powerful upgrades.”

Chart plotters at each Helm

Over the past 15 years we’ve sailed 70,000 nautical miles across the Atlantic and Pacific Oceans.  We’ve visited over 35 countries and truly love our boat/home. 

However, we have never had a chart plotter at the helm.  We’ve had a handheld Garmin 73 (with satellite and tracks), but no chart plotter.  We’ve had to either zip into the salon to see the multitude of charts on the navigation station or rely on Navionics on the iPad.  Not ideal, but it worked for us.

Finally, it was time to upgrade the helms.  The first thing we did was fabricate a new pedestal extension at each helm.  Each helm station has a pedestal and an additional small extension where our Garmin holder, Raymarine gauge, stereo remote, (2) anchor controls, a small control panel, and the IridumGo antenna lived.

Matt disconnected all of the gauges and instruments first. Then with loads of patience he removed the 5200 holding the back extension.

We cleaned up the front and back and removed the 5200 excess.  

Our friend, Ian on Tavake (a Catana 431) told us to use fabricator Scott Banks.  Super nice guy! 

Scott came out, took a bunch of measurements, gave us a reasonable quote, collected the pedestal extensions, and told us he’d be back in 2 weeks. 

Unfortunately it took way longer than 2 weeks, but we are very pleased with the final product (see below).

Chart Plotters

We purchased (2) B&G Zeus 9 Chart plotters from Marine Deals.  It took 6 weeks to get delivered and cost approximately $1400 USD each.

The other controls (small control panel allows us to turn on/off 6 items, stereo remote control, and (2) anchor controls will go on the new pedestal extension.

We had to move the existing Raymarine P70 gauge to a new Marine Pod mount which will sit to the side of each helm. 

Marine Pods for Raymarine Gauge

We could have made the pedestal extension large enough to accommodate all of our equipment.  However that would block the view from the helm seat. 

In order to keep the view we went with a smaller pedestal extension and a marine pod mount for the gauge.

We purchased (2) marine pod mounts to move the Raymarine Autopilot (ST60) gauges to the sides of the pedestals. 

The pods are called Seaview SP1BOX Marine Pod Kit . We bought them on ebay for $95 USD each

LC Hydraulics (Phillip) fabricated two mounting holders for the new PODs.  It took about 2 days and cost $855NZD.

The white square is the pod and the two holders are for each helm.

The new upgraded helm stations are amazing! 

With the new helm extension holding our chart plotters and our new pod’s holding our gauge!  

Purchasing and Contact Info:

  • Scott Banks, Fabricator, Whangarei, NZ +64.22.380.3972.  Fabricated the helm pedestal extensions and the window rain flashing
  • Chart plotters purchased from Marine Deals, www.marine-deals.co.nz
  • Raymarine gauge mount : Seaview SP1BOX Marine Pod Kit New Open Box Accessory Mount for GPS VHF Display purchased from eBay
  • Marine Deals +64 09 281 3150, www.marine-deals.co.nz, Auckland, NZ
  • LC Hydraulics, www.lchydraulics.co.nz/, +64.21.0285.5072

Design specs of the chart plotter that we used as a base for the helm pedestal extension.

Our blog posts run 10-12 weeks behind actual events.  

We started working on these little upgrades as soon as we arrived in New Zealand (Oct.2025-Jan.2026).

These are just a few of the massive projects we completed. 

See our full list on our “Hauling out at Norsand Boatyard” blog post.