February 24, 2010

The new Lighthouse windlass I ordered weeks ago arrived yesterday. It was frightfully expensive, but when I unpacked it, I found it was one of those rare marine items that actually has the quality that reflects the cost. It's both massively and beautifully made. The shipment weighed 132 lbs, which created a bit of a challenge when it came time to get it out of my truck. (The warehouse staff at work, where it was delivered, helped me load it.) Because I didn't want such a tempting and expensive item just sitting in the back of the truck for weeks while I prepared the deck and wiring for installation, I had to figure out a way to get it in the house without breaking my back. I ended up disassembling the shipping crate in the back of the truck and removing each major component separately. The motor alone was probably only about 40 lbs, but the windlass assembly was a good 65-70 lbs by itself. I went through the instructions and components to see what I was in for. As I anticipated, it will be a pretty big job. One pleasant surprise was that the package included a relay and switch. It requires six half-inch bolts for mounting the unit, which doesn't sound like much until you check the cursed West Marine catalogue and find that in the length I'll likely need, they're $5 each! Fortunately, I found a place online where I can order them for about half that.

I also measured how high the chain would be above the windlass base to get a sense of whether or not I'd need to raise the chainstopper more. It's going to be close, depending on how high the anchor roller is. Most likely, it will need that additional inch.

Once I had things reasonably sorted out, I sat down with a glass of Cabernet and savored both the wine and the fine piece of machinery at my feet. The windlass itself is all beautifully polished stainless steel, so it will never corrode like the typical aluminum or mild steel windlasses. The yellow fluted base at the bottom end of the motor is a silicone rubber casting, with a clever pull-out bottom that allows access to the electrical terminals, but maintains a seal.Once I had mellowed out a bit, I did a bit of head-scratching about how I'm going to build the rest of the windlass base on the deck. The difficulty is that the deck is convex and has a raised narrow platform in the center where the old windlass was. I think I've come up with a workable and effective method, but it will will require some fancy fiberglass work. Stay tuned to see if it works!

February 22, 2010

Since the weather hasn't been cooperating, I've been unable to work in the boat yard. Nonetheless, I've been able to track down some supplies and get some good things done in the shop. I bought a foot of 4" square, 1/8" thick stainless tube to make a base for the chainstopper that would bring it up to the level of the chain as it runs between the windlass and the bow roller. It was unpolished, so I spent an hour or so sanding and buffing three sides. I had a 5/16 inch cobalt drill bit (which is what it takes to drill through stainless), so that was the size I chose for mounting holes. Using water as the drill lubricant (a tip I got from a machinist), the drilling went more quickly than expected. Unfortunately, the holes in the chainstopper I bought were 1/4 inch, so I had to drill them out so that they would match the holes in the base tube. That was no big deal in itself, but it meant that the counter-sinks for the heads of the flathead bolts wouldn't be big enough. Because I didn't want to spent $100 on a 3/4 inch cobalt drill bit (if I could find one), I ended up grinding down the bolt heads using a grinder and the drill press as a makeshift lathe. It worked fine. I scrounged some free pieces of white acrylic sheet from TAP Plastics' scrap bin, cut them to size for end caps for the stainless tube, and then cut rabbets around them, hoping to get them to be a press fit. Amazingly, it worked perfectly. When the new windlass arrives, I'll see how close I came to getting the chainstopper the right height. I'm anticipating I may need to raise it a bit further by putting the stainless tube on top of a 1-inch teak base, which is no problem.

February 15, 2010

Work on Circadian has been interrupted a bit by a trip to Los Angeles to see Carol and two weekend days spent prepping and showing my other boat (now for sale), By the Wind Sailor. I did manage to get a few things done in the shop and squeezed in one day at the yard.



In the shop, I've been sanding and varnishing the aft cabin head door and one of the hanging locker doors.

In my day at the yard I was able to complete the radar antenna installation, pull the new VHF antenna through the mast, and trace and check the existing wiring. Other than the normally obscure instructions, the antenna went on fine.
I used the old VHF antenna wire as the messenger to pull the new one through. In the process, I quickly found out why it was no good: it broke apart a few inches from the masthead end. As usual, the first 50 feet through the mast was easy; getting out the last 3 inches was the challenge. Removing the chrome exit tube fitting at the bottom of the mast finally did the trick.



I used my truck's battery and jumper cables to test and trace the existing mast wiring. I was beginning to get depressed when neither of the first two wires I checked lit up either the anchor light or masthead (steaming) light. I labelled them "unknown." Things changed quickly for the better, however. The next two checked out for the anchor and masthead lights, and were labelled accordingly. The two "unknowns" logically, then were for the two spreader light wires. I found and bought a new masthead light bulb at the yard's chandlery and installed it. I also installed the LED bulb I had bought at West Marine for the anchor. Both worked great and I left a happy sailor that day!

January 31, 2010

I spent a few evenings during the week cutting new louvers for the bottom of the aft cabin hanging locker (to replace the four that were missing) and filling and fairing the new windlass base.
I had brought home one of the original louvers as a model for the new ones. Each was about 6 inches long and a quarter of an inch thick. Only three-eighths of an inch wide, there wouldn't be much to hold onto putting it through the table saw, and I had to cut two parallel faces at a 45 degree angle. The challenge would be to cut them all precisely and still have all my fingers when I was done. I clamped a couple of feather boards to the saw to guide the small pieces past the blade and pushed them through with plastic and wood pushing sticks. It was still scary, but I was careful and it all worked. I was glad I had an Inca saw with a Forrest blade! After cutting, the louvers required very little sanding and fit perfectly when I checked them later.

I ground down the new windlass base to round the corners and even things out. That was followed by a final layer of glass cloth and epoxy (which bonds better to cured polyester). A little filling with epoxy with enough microballoons added to create a filler the consistency of peanut butter was followed by a lot of hand sanding with a straight board after it cured.




Today was the first day without the threat of rain, so I was able to tackle mounting the radar and threading the antenna cable through the mast. As I anticipated, mounting the support bracket was pretty straightforward; it was fishing the antenna cable through the mast that was tough. Even simply drilling the 3/4 inch holes for it had its hazards. The first time the drill bit jammed in the hole, the powerful 1/2 inch electric drill damn near broke my wrist!


While the task would have been impossible without the wire fish tape I had bought, it was still difficult. I soon discovered that there was no way to extract the end of the tape from the hole by the radar mount, which would have allowed me to pull the antenna cable down to the base of the mast with the connector at the right end. Instead, I had to thread the fish tape from the top down, struggle to get it out the base, attach some 1/8 inch line to it, then pull the tape and line back out the top. I then attached the cable to the line and pulled it back down the mast. Because the base of the mast already had a couple of large drainage holes in the bottom, at least I could peer inside, see what was going on and pull or push things around with a bent coathanger wire. When I finally got the plug end of the cable down to the base, it was these extra holes that made the effort to get the plug back out the hole merely tedious and frustrating instead of completely futile.



On board the boat, I took measurements to determine the lengths of the heavy electrical cable I would need to connect the new windlass to the batteries. At $5/foot (which is half the cursed West Marine price!), you want to get it right!


I taped a piece of plastic sheeting over the port light I suspected of leaking above the v-berth, buttoned-up, cleaned-up, and called it a day.