Saturday, September 18, 2010

Creative Deconstruction

I'm starting to think that they built this boat without even considering that someday someone would take it apart. All the deck hardware, save for a few items at each end, has been removed.

The removal of the stanchion bases just about killed me yesterday. Contorting into spaces and positions that my old muscles were not intended for. At several points I was holding on to a ratchet that was slipped on to a nut I could no longer see, while reaching outside as far as I could strain against the porthole, holding a screwdriver in a pair of Vice Grips so I could reach the slot on a bolt that was six inches beyond the reach of just my arm. I didn't do any boatwork today. Tomorrow, if it doesn't rain too long, I'll begin grinding a small radius all along the sheer for glassing the Hull/Deck joint.

Thursday, September 16, 2010

End of Summer Wrap Up

Whoever thought that my Trucker Tools would come in handy while working on the boat? The Rub Rail and the Toe Rail have been removed from the gunwale. Some of that work was with a crowbar. The deck is the current big project. I am working on backing the deck hardware [backing plates from previous post], patching some defects, replacing the cockpit floor and glassing in the Hull/Deck Joint - though not necessarily in that order.

Since early June, I've been driving part time and working on the boat full time. It turned out to be a great Summer to be a part-timer. I had the privilege of being able to pitch in and help with some family things that came up as well. There were several projects needing more time than money that I completed and scratched off my list. The list is still long, but the time spent this Summer will help to increase the possibility of getting the boat wet next year [the sound you hear is me rapping on the nearest wood].

There were, of course, some surprises along the way. The damp core in the Aft Starboard Quarter, while still small, was about twice what I had thought [pictured right]. Other surprises were simply added to the To Do List. The cabinetry in the galley came out to reach the port side jib car track bolts. The main cabin actually seems roomier without it. So now, I have new plans formulating for the galley.

The portlights are in and are quite nice. They were worth the trials and tribulations of the the install. The cabin is much more watertight. In the Spring I'll have to finish by replacing the two larger ports.

Monday, May 17, 2010

Backing Plate Factory

I haven't been on an assembly line in a long time. This week I set up to epoxy coat each side of the backing plate parts I had made. The backing plates are two layers, one of plywood and another of tempered hardboard. The plywood is the strength, and the hardboard is the hard surface. We've all seen screwheads or washers bite into the soft surface of plywood, the hardboard will prevent this. There will be plenty of stress on the various deck hardware from wind gusts or while tacking. I was shocked at the lack of backing of the winches, padeyes, etc. There are plenty of signs of hard use on the boat, the hull especially, its amazing that no hardware was yanked out of the deck.

The backing plate parts are epoxied and now need to be laminated together. In the meantime, I finished epoxying [see a trend here] the spacers for my opening ports. The ports I ordered should come in this week. The backing plate project is my fill work. The Port Installation is going to be a large, yet tedious, project. Hopefully I can get it done in 3 or 4 weekends. I'll keep you posted.

Wednesday, May 12, 2010

Call of Ports :: Ports of Call

In the last couple weeks, I decided to bite the bullet and get new ports. I knew I had to, really. In an effort to hit a price point in the 1970's, Cape Dory installed plastic ports rather than bronze on their 28 footer; my model boat. After a couple years, with the plastic ports somewhat unpopular and likely making little difference on the overall price, Cape Dory went back to bronze. My ports were showing their age and one was damaged. For a water tight cabin, in the rain or in a storm at sea, I needed to replace the ports.

I removed the old ports and began replacing some soggy wooden spacers with epoxy. This week, I ordered three car payments worth of new ports. Bronze was out of the question because of the cost. I ordered six 5" x 12" Tri Matrix ports from New Found Metals in Port Townsend, WA. The company rents out a drill template and sells the appropriate counterbore. The ports are reinforced composite with stainless steel hardware. It will be nice to have bristol looking ports with fresh screens. I still have to replace two larger ports but I'm having trouble finding something the same size. This may require some fiberglass work on the cabin to accomodate ports that are smaller in one or the other dimension.

Also last week, I mapped out all the backing plates I need for deck hardware. Cape Dory has a good reputation for building very solid boats. I have not, however, been impressed with the way my deck hardware is attached. In almost all cases, backing of deck hardware was either inadequate or nonexistent. It was this latter that concerned me the most. I have cut out plywood and hardboard blanks that will be epoxy coated and then laminated together for proper backing.

In other small news, I ripped out the cabinetry in the head. The sink countertop was rotten from one of those leaky ports, and the medicine cabinet was in the way of getting at the chainplate bolts. The face of the hanging locker may be next. It, like the other cabinetry, is in teak-ish paneling and is kind of dark. I may add some white panels here and also in the main cabin to brighten up the place.

Here's keeping my fingers crossed for good weather on Thursdays and Fridays.

Friday, April 23, 2010

Hangin' In the Hanging Locker

Some days you just have to take the good with the bad and keeping going. Besides, its still April. I shouldn't even be able to work on the boat yet - in Michigan. So I had a frustrating and stupid day at the boat on last Friday. Bad Boat Karma.

In order to let the Sun come up for a while before we arrived, Dad and I waited until mid morning to head down to Douglas. I had a couple things to check on. And, though it is never hard to convince Dad to come along, I especially needed him this week to hold a screwdriver on several bolts on deck while I contorted myself into the hanging locker [closet to you landlubbers] and remove the nuts on the other end. The bolts are those that hold the chainplates, and ultimately my mast. Cape Dory employed a unique system that avoided some of the disadvantages of modern chainplates jutting through the deck or cabin of a sailboat. The system, of course, has a few compromises and disadvantages too.

The first problem I encountered, and should have anticipated, was the length of the bolt. Once I climbed into the locker, I realized that my sockets weren't deep enough to reach the nut. To get into the locker, I had to hang from two door jambs, put my feet inside [put left foot in and the left foot out . . . ] and twist my hips and then my shoulders to fit inside the opening. Spare tools were on the shelf above the closet, so I was often blindly reaching out and over my head to retrieve some other wrench.

The boat is only a half hour from home. Why we didn't just head back to go through Dad's extensive collection of deep sockets, I don't know. It was my decision and I decided to go look at the local hardware; five minutes away. The town of Douglas is small, the hardware store is an appropriate size for the given population. The only deep sockets the store had were a couple spark plug sockets; neither the right size for my bolt.

The Hardware store did, however, have a set of wrenches with ratchets on the box end. I decided to buy the $25 ratchet wrench set rather than looking somewhere else for a $4 single deep socket. Or, for that matter, heading to Hudsonville and borrow one of Dad's. My cruising kitty is doomed to bankruptcy.

Back at the boat and back in the closet, I was reaching up into the small space near the hull and deck joint. The wrench was flat like a typical wrench. The ratchet on the box end tightened from one side and, flipped over, it loosened from the other. The package claimed that it could work with as little as 5 degrees of swing. A good thing, because that is about all I could muster in the small space where my hands were. Clicking back and twisting in a small swing, I began to realize that taking these nuts off was going to be an arduous task. Just then, the wrench flipped out my fingers, up in the space I can't see, and tumbled between the hull and the closet liner; down toward the keel.

One of my most often used tools is a shop mirror. The extending handle allows me to peak into all kinds of spaces. I reached blindly above my head and felt around for the mirror. Deploying the mirror with my safety light, and with a flashlight, from all angles and contortions, I could not see the wrench. I tapped around on the liner but couldn't really decide if I heard any sounds a lost wrench might make. I tried laying on the floor and shining the light up from the bilge. No wrench.

An unused new toy, I mean tool, came to mind. On inspiration, I grabbed the cheap knock off Multi Cutter, a vibrating blade tool that cuts through all manner of things. I lined off a rectangle with a pen and straight edge and cut a whole in the closet wall. No wrench. I tapped some more and cut another hole in the vicinity of a wrench-sounding tap echo. Nothing. Two more small holes and twice more - no wrench. The hull is really close to the liner where I was cutting. The wrench must not be this low, I decided to make a long cut a bit higher. And . . . no wrench. In a surreal game like Whack-A-Mole in reverse, I tried spying with the mirror from the large holes while stabbing the flashlight randomly in the other holes. Um, no wrench.

You just don't know what a purely hateful feeling it is to be standing in a boat, pissed off, with a wrench just inches from your toes yet inaccessible. Not only that, I can put up with a lot to be on a boat. The nature of boating is mechanical frustration in beautiful settings. However, I'm pissed off with a lost and brand new wrench in a boat that is sitting on the solid ground, fifty yards from the nearest water. My next poorly conceived management decision was to call Lunch. My intention was to drive up into Holland, get something to eat and go to Menards for a deep socket. Once again, I can't tell you why I didn't call lunch in the vicinity of Dad's toolbox.

We drove up to Holland and I got my 9/16" deep socket. I ignored this odd feeling that I should buy 1/2" and 5/8" as well. From Menards, Dad and I found some lunch at Wendy's and headed back to the boat.

To top the day off, I had Dad holding the wrong bolt! I crawled and contorted my way back into the hanging locker. With my brand new deep socket, I called out to Dad, "OK, the forward bolt of the forward fitting." I started turning. At times, Dad was trying to turn the head of the bolt with a large slot head screwdriver. I got the nut off of each of the two bolts and tried pushing them up and out. Luckily, the previous person to touch the bolts had used a lot of sealer. When I went up to see if we could turn the bolts or pry the fitting up, I stopped to look at the slope of the coach roof and the placement of the ports near where Dad was sitting. I jumped back down the companionway and peaked out at the fitting near Dad's feet. All that time, he had been holding the bolts on the fitting I told him to, but I was loosening the nuts on the next fitting aft. I called Supper.

Tuesday, April 13, 2010


A new year begins! Another belated post, but two weeks ago, it was a beautiful sunny day. I went running down to Douglas and uncovered my baby. It was beautiful and sunny and . . . I hadn't had near enough sleep. I tried to kill myself Thursday came off the road and headed to the boat on 1.5 hour of sleep. However, I got some rest and put in a great day on Friday.

There is now only ten or twelve feet of wire left on the entire boat! It all had to come out. My philosophy is that in order to know exactly what I have, I have to replace all the wiring. If there were any corrosion or damaged wire anywhere aboard, I wouldn't know it until something quit working. And even then I wouldn't necessarily know the location of the problem; better to start fresh. In order to start fresh, all the old had to come out. I left a few stray bits to trace a few wire runs I couldn't figure out.

After I got started, I was increasingly comfortable with the choice I had made. Behind the fuse panel was a mess, but I didn't realize HOW MUCH of a mess until I started tearing it out. She'll have a couple new electrical panels and LOTS of new wiring when I get done. Also, a couple new house batteries and a new starting battery. As I do more research and make preliminary choices about equipment, the battery budget, in Amp-Hours not in Money, is coming together. Later are choices about heavy duty alternators, solar panels, wind generators and other fun expensive stuff. "Stuff" being a nautical term, of course.

Belated Year End Wrap Up for 2009

This is a belated Year End Wrap for 2009. The most important event of the year was the moving of the boat. I'm saying "the boat" now because I am in the midst of negotiating the renaming with myself.

Dad had been accompanying me to Bay City to do boatwork. After being driving all week, Dad and I drove 3.5 hours over to Saginaw Bay to work. It was difficult, at best, to get the gumption up to do anything significant. Dad was inspired, after speaking to Mom, to front me the funds to move the boat. The first quote I got, three years ago, was outrageous and I never considered moving the boat. With the backing, I searched anew and found a company out of Holland that was amazingly reasonable.

We got an early start last year. I had finished stripping the bottom paint and started sanding off the last blush of it. This was quite a job; a 28' foot hull to a depth of 4 feet with a palm sander.

The boat was loaded on to a very cool adjustable trailer and hauled from Bay City to Douglas, near Saugatuck. There she was dropped onto a cradle and began enjoying her new surroundings. The trip had turned out to be less than I imagined and the new marina actually charged a little less for yard storage!

Her new home is Tower Marine on Kalamazoo Lake

I was in paradise, the boat was now only 30 minutes away from home. If I forgot a tool or something, I can just run home and get it. Amazing. And the work began. The Hull Sanding was finished and work began to fix some issues on the hull itself.

There were typical dings and gouges that only needed filled, but there were also a few places where I wanted to grind out some major surface crazing and reglass. It had been quite a while since I had dipped my hands in polyester. The first patch was a little thick, but like the Tin Man, the rusty skills I had earned in the back of a boat plant in Florida, came back with a little oiling. I was quite happy with the results.

I worked into Late October until the weather began to threaten. With a new backbone built, I covered her up on the last weekend before the first snow flew.