Tag Archives: repairs

Wash down pump replacement

Servicing our Girl: Sugar Shack

What do you do on a beautiful day in paradise?  Get dirty?  We had a few boat projects that needed to be completed in calm weather (no wind and no swell).  So, we set out to do some maintenance and servicing of both Sugar Shack and Sweetie (our dinghy). 

Anchored in calm waters with very little breeze made it much easier to accomplish these specific projects.  We dropped the hook at North Totegegie where we had beautiful views. 

Servicing the Boat in Paradise

Servicing the Boat in Paradise

Windlass Service

What is a windlass?  It is an electric wench that raises and lowers our anchor and anchor chain. It is a very important part of our boat as it would make anchoring nearly impossible without it.  In a pinch, we can manually raise and lower our anchor using the hand crank method.  However, we have 100 meters of 10mm stainless steel chain attached to a Spade x140 anchor that weighs in at over 65lbs.  Imagine cranking all that chain and anchor up by hand – no thank you!

Our Lewmar Ocean 3 windlass (2000 watt) was running a little slow when raising the chain.  Once it got going it was fine, but the startup was less than optimal.  Not a problem, just needed a little love.  We are at anchor with our anchor chain connected to the windlass.  Can’t rightly service the windlass without removing the anchor chain, right?  First things first, Matt ties a line to the last link of chain (just at the rode) and then secures it to the anchor roller so he could remove the pressure off the windlass.  Then he jumped in the hole (locker) and cleaned the brushes and removed the corrosion.

Servicing the Windlass

Servicing the Windlass

Not yet at 100%…it might require a more comprehensive servicing in a month or two.  For now, it is better than it was and that is good for us (maybe at 95%).  A few days later, Matt took the windlass apart and cleaned all the connections.  He found a loose wire that was the culprit and now the windlass is running perfectly!

Tail Tails

Do you know what a tail tail is?  It doesn’t have anything to do with your posterior or an animal.  A tail tail on a boat is an indicator of how your sails are trimmed while underway.  They are small, light pieces of fabric attached to the sail.  When the sail is trimmed correctly, the tail tails on the windward (inside) and leeward (outside) of the sail will stream backwards.  That’s when life is good.  If the sail needs trimming the tail tail will either fly up or down indicating the need to tighten or loosen the jib sheet (working line) to give you optimal performance.

Our tail tails were very sad and in need of servicing.  Easy enough job when there is no wind.  Matt had to drop the sail onto the deck in order reach all the tail tails.  You don’t want to do this in windy conditions as your jib will be flopping all over the place.  We bought a kit which made replacing them super easy.

Washdown Pump

Our Jabsco washdown pump is located in a locker near the mast.  This pump provides pressure to our hose to enable us to wash down the boat, the anchor chain and pretty much anything we need.  It is great because we can use it with salt water or fresh water depending on how the valve is turned.  We usually hose things off first with salt water, then do a final rinse with fresh water.  Why is that?  Because we have an abundance of salt water and a very limited amount of fresh water.  Our pump was very corroded as it is in and around salt water and salty air.  It worked, but it was limping along.  Instead of ‘servicing’ we decided to replace her.

The pump is only attached with a few screws and clamps.  Matt had it replaced in under an hour.

Wash down pump replacement

Wash down pump replacement

Servicing Sweetie – Our Dinghy

I had intended on putting the work done to service Sweetie on this blog, but it was so extensive that I ended up giving it her own blog post.  Stay tuned for “Dinghy Spa for Sweetie.”

Events from this blog post occurred during the month of January 2021.  Our blog posts run 8 weeks behind our adventures.

Smack, Crack, Fall. Alternator Down

This post is a long time in the making so bear with me.  It all started back in mid-February 2020 when we were trying to leave the Marquesas.  One alternator decided it did not want to be attached to the engine…

We rose early on the morning that we planned to leave for the Gambiers.  Not because we wanted to leave early, but because we anchored on top of another boat’s anchor.  We had to start the engines and move our boat forward so they could safely retrieve their anchor.  Not a big deal, but an early morning.

The Bay of Virgins (in the Marquesas) is a gusty little devil, with katabatic winds coming down the valley.  All good, took a while but we were able to maneuver out of the other boat’s way without dislodging our anchor.

While Matt waited for the other boat to sort out their anchor, he heard a loud clunk.  Sort of a smack, crack, clunk.  He figured I had opened or closed a bilge or something.  But, no, not me.  He did not mention it to me right away so I was clueless.

A few hours of going over the forecast and future forecast, we finally decided to get going.  As usual the “pre-flight engine checks” were in-order.  This time a surprise of all surprises. 

Surprise Surprise

When Matt opened the port hatch to the engine room, he saw the auxiliary alternator that charges the house batteries, was missing in action.  WTF?  This is a 50lb, white alternator.  It’s a hard thing to miss. 

The belts were not on the front of the engine.  Turns out the engine mount that holds the heavy alternator gave out, ¼ steel plate broke right off.  The plate that holds the alternator is also part of the engine mount.  So, when we go to fix it we will have no use of the port engine. 

Pretty sure that was the smack, crack, clunk, sound he heard earlier.  Guess we will be looking for a welder in the Gambiers.

Project on Hold

A week after we arrived in the Gambiers, we attended a Sunday Funday BBQ in Taravai where Matt was able to ask several people about local welders.  It appears there are two people who have the tools and capabilities.  One cruiser had something welded by the main group of welders and he was not impressed with their work.  The other is a friend of a friend that we would have to hunt down.

Looks like we will put this project on the back burner for a few weeks.  This is a secondary alternator that is used to charge the house batteries.  So, without it we just have to use the Starboard secondary alternator to charge the batteries.  We have 4 alternators (two for the engines and two for the house batteries).

Lucky Break

Fast forward past some down time, then the corona virus 45-day quarantine, and we are at 3 months later.  Our friends on Storm Along have a metal boat and Niels is a welder with all the welding equipment. He has agreed to help us out if we can get some extra steel for the support brackets.

We come up with a game plan.  Matt and I need to find some steel to reinforce the plate in three sections.  Then we will meet Nils on the beach to weld the plate back together.  Now, to find some steel.

Stefan to the Rescue

Fast forward a few more weeks and we are back in the anchorage of Rikitea in Mangareva.  We asked our local friend Stefan if he knows anyone who can do some welding for us.  He works at the school which has professional technical training and we heard they teach welding.  He asked what we needed and to our great surprise he had all of the tools, equipment, steel, and supplies.

Stefan cut three pieces of steel to Matt’s specifications.  The triangle will be welded to the vertical and horizontal pieces.  The long flat bar will be welded between the alternator plate and the engine plate on the bottom. The short flat bar will be welded between the same two plates but on top.

Welding Begins 

We met Niels at the beach with all of equipment.  We used our 220v Honda Generator for power.  It worked great for the grinding and for short welds.  Niels was able to make the initial weld holding the two pieces together.  Then Niels and Matt started off by grinding the pieces for a better weld.

Then the boys attach the first support bracket across the bottom of the two plates.  The image below shows them testing placement, then grinding the bar, then Matt holds it in place for initial small welds and then Niels tries to do a long weld.

Unfortunately, the Honda generator was not strong enough to power the welding equipment which required a 100 amps (at 220volts).  Looks like we need a Plan B.

Plan B

We visit the local “Commune” where the islands has most of its machinery and a welding shop (the place mentioned above that did not do such a good job for another sailor).  They graciously allowed us to use their power to complete our job.

Commune Building in Rikitea

Commune Building in Rikitea

Matt got to grinding the remaining parts while Niels welded.  Perfect set up to complete our project.

The welding was complete about 90 minutes later.  The big ugly weld was not Neils but the previous weld we had done in St. Lucia.

Next, Matt sprayed a anti-corrosion paint and two coats of Volvo green paint to match the engine.

Project done!

Sugar Shack is back on the water in good company with 2 other Catanas

Lightning Strike: The Highs and Lows

Originally, there were a dozen posts documenting our lightning strike catastrophe and the claims process.  But after 6+ months of living the hell, we decided not to publish any of those posts. Instead, we will publish one post and focus on the highlights and the benefits rather than all the negativity surrounding this journey.

If you are a cruiser, please contact us for your copy of “Prevention and Preparing for a Claim” which outlines key measures to take prior to claim.  We created this document with the sole purpose of helping others avoid issues and is based on our experience with our insurance carrier and being in the Pacific.

Despite all the setbacks, Sugar Shack is back on the water and we are a lot more knowledgeable of all the boat’s systems and parts.

HIGHLIGHTS:

A lighting strike can give you the blues.  However, we were elated each time new parts arrived.  It was exciting and surprising to see what arrived each time.  There was no rhyme or reason as to what arrived or when.  Some parts ordered way after others arrived first and parts ordered first arrived last.

Arrival of boat parts

Arrival of boat parts

Waiting Game

While we waited for parts to arrive, we did everything we could to prep the boat for installation.  The most time consuming project was rewiring the boat.  As you can imagine, a lightning strike can do some damage to wiring/cables.  Old cables in lower left image.

Out with the old, in with the new: Cables

Out with the old, in with the new: Cables

The Team:

We had a good team working on electronics, mechanical, and refrigeration.  Of course, Matt was extremely hands on, supervised all the work, and jumped in to ensure it all was properly executed.

AG Marine Descends on Sugar Shack

AG Marine Descends on Sugar Shack

Flaco, the tallest AG Marine worker contorted into the smallest places:

AG Marine get's into Tight Spaces

AG Marine get’s into Tight Spaces

Navigation System

All the equipment at our navigation station had to be replaced.  It was a bit of a disaster for many months as we awaited for parts to come in.  Diego had to build a new face panel to accommodate the new parts, but the end product came out really nice giving us a much cleaner, less cluttered space.

Navigation Station & Equipment Rebuilt

Navigation Station & Equipment Rebuilt

Solar Panels:

Our solar panels were fried and had to be replaced.  The new panels had different specifications, so we had to modify our existing rails to accommodate them. 

New Solar Panels Providing Energy

New Solar Panels Providing Energy

DC DIGITAL SWITCHING: POWER

The last to arrive, even though it was the first to be ordered, was our main digital switching or AC/DC control system.  Of course it had to be built, programmed, and calibrated before being sent to us.  Catana built their boats with cartes which are no longer being manufactured.  So, we replaced the system with a C-Zone system.

C-ZONE AC/DC Main Control System

C-ZONE AC/DC Main Control System

The old Digital Switching Control Panel (lower left photo) was completely destroyed by the lightning strike and is no longer available. C-Zone replaced it, which is a complicated beast, but gives us much better monitoring and access to everything remotely.  We can now control systems from this main control panel, a sub-control panel in the master suite, through B&G, and on an iPad.

DC Digital Switching Panel

DC Digital Switching Panel

BEAUTIFICATION:

We also took care of standard maintenance including wash, wax, bottom job, and prop speed.  I love the mid-way photo of the wash wax below (middle photo).

Sugar Shack get's a bath and a new wax

Sugar Shack get’s a bath and a new wax

The last color of our skirt was red and they sanded it down, painted a light blue which we didn’t like and changed it to a dark blue, which we love.

Sugar Shack get's a new skirt

Sugar Shack get’s a new skirt

Prop speed is used by a lot of fishing and speed boats.  We have never applied it to our props because it’s very expensive.  But, Bristol Marine included it for free with the cost of our bottom job.  Prop Speed prevents marine growth from bonding to metal surfaces below the waterline.

Prop Speed on our props - it's a first for us.

Prop Speed on our props – it’s a first for us.

Stepping the Mast:

Stepping the mast requires a village.  We had a rigging crew (3), yard assistants (3), AG Marine (5), painters (2), crane driver, lift drivers (3), launch slip helpers (4), a diver, and of course Matt and I.

Stepping the mast includes: carefully positioning the mast, connecting all the cables, securing the standing rigging (and tuning it), and putting the lazy jacks, sail bag, main sail, jib, and reefing lines all back on.  Then they touch up the bottom job where the blocks were located, move the crane, bring in the lift and slowly lower us into the water.

Stepping the Mast Takes a Village

Stepping the Mast Takes a Village

And she floats!  Thank God!  We had several issues once she was in the water, but we worked through them.  Both engines wouldn’t start, but after 20 minutes they were purring like kittens.

Sugar Shack is back on the water in good company with 2 other Catanas

Sugar Shack is back on the water in good company with 2 other Catanas

Outstanding Items After Splash (since repaired):

  • The radar doesn’t work (we have to exchange it for another new one),
  • Autopilot smart controller LCD screen is still funky (we are going to live with what we have)
  • The new starter battery was dead (charged her up)
  • Frigeration is on the fritz (spent 4 days working on it).

The lightning strike slowed us down and beat us up, but we are in the water and one step closer to continuing our adventures on sv Sugar Shack.

MPV Celebrating Our Departure

MPV Celebrating Our Departure

Any lightning strike is tough as you never know what it will impact. Some parts work at first, then fail, or fail, then work.  Unfortunately, there is no proven way to prevent lightning strikes.  All you can do is try your best to stay out of bad weather or zones that are prone to lightning strikes.