September 26, 2011





Well, it was another week in which life interfered with my plans, albeit all to the good.  The house is in escrow again with a pending sale, and I even got a back-up offer.  Unfortunately, the buyers want an FHA loan, which requires an FHA inspection which requires a lot of PITA health and safety standards be met.  As a consequence, I had to abandon some of my planned boat projects in order to make some house modifications to try to meet the FHA standards.  These included adding handrails to porch steps and pouring a new concrete step for the basement.  There's more to do, but that's what I accomplished this week.  In between house projects, I made a quick run to the boat to check the fit of my new stemless wine glasses in my new glass rack and mark the trim line for the laminated dinghy transom reinforcement I started last week.  I also checked the autopilot again, and it worked as it did last week.  Still haven't talked to Wil at WH yet.



Back home in the shop, I trimmed the laminated dinghy transom, rounded the edges with the router, and applied a thick coat of epoxy.                                                                                        

That was about all I was able to accomplish because I had to quickly pack up and jump on a plane to LA to visit Carol.  It had been too long, and with everything that had been happening with the house, it was tough to make travel plans.  Nonetheless, I was at the airport at sunrise on Saturday, and it all worked out.


Because I wired up Carol's new retro stereo system for her while I was there, I was able to cajole her into doing a bit of sewing for me.   I had an old canvas dinghy cover that needed the seams restitched and thought we might make a tablecloth for the little folding table for the boat.  We scoured the fabric store until we found some fabric we liked and headed back to her place for a sewing bee.  Well, her little vintage Singer was, not surprisingly, unable to handle the heavy canvas of the dinghy cover.  The tablecloth was no problem, though, and since we had extra fabric, Carol made a spare.  Thanks, Carol!






September 19, 2011

It was a hectic week full of ups and downs.  Had what looked like a good cash offer on the house that fell through because grampa didn't like it.  Quite an emotional bounce.  Between showings I worked in the shop finishing up the outboard, making a new fuel pickup tube, building a glass rack to add to the dish rack, and cutting some plywood to reinforce the dinghy transom.

The original pickup tube in the outboard's fuel tank was flimsy plastic and had fallen apart.  Heck, that could have been the original reason the outboard didn't run.  After the quickfix didn't work, I decided to do it right and build one out of metal if possible.  The tricky part was that the tube needed to come out of the inside of a male pipe thread fitting.  It took about an hour in the hardware store to finally find bits that could be put together to work, it just took some soldering with a torch.




I now had everything ready to see if the outboard would run after the carburetor rebuild and other work.  If it ran well, I'd pretty it up by removing some ratty old service decals and adding a new coat of paint.  I loaded everything up into the truck and headed out to Hidden Harbor.  By the time I arrived it had gotten pretty darn hot and the place had been invaded by butterflies.



When the big moment came to test the motor in Scott's water barrel, of course I had an audience.


Nothing happened after the first couple of pulls.  Fighting back panic, I suspected the new kill switch key I had gotten was not thick enough to activate the ignition.  I disconnected the secret brown wire that circumvented the kill switch and tried again.  The motor roared to life!  A couple of turns of the idle adjustment screw to bring the rpm's down and she ran like a top.  Even the transmission linkage was fine.  Life is good!


I brought my outboard and a smile back to the shop where I knocked off the corrosion and repainted everything but the cover with the closest match I could find in Pep Boys.  I also fabricated a new kill switch key from thicker HDPE, which I'll test later.


When I had finished with the outboard, I built a new mahogany glass rack to go with the new dish rack.  Again, everything was salvaged or leftover, so it cost me nothing but elbow grease.  It fit fine and looked pretty good, but I need to add some molding to the front edge and find shorter wine glasses.




Then it was back to HH to mold a plywood reinforcement for the dinghy transom.  The 5 hip outboard was a bit much for the dink, and there was a crack in the fiberglass lip where the engine mounts.  The P.O., as usual, had done a quick-and-dirty make-do, which was both ugly and not strong enough.  My plan was to use the dinghy transom as a mold on which to laminate thin plywood to conform to the curve.  I repaired the crack by first filling it with epoxy and thickener, then laminating two layers of cloth over the crack and around the lip.  When that was cured, I laid up three layers of 1/8 inch plywood glued together with epoxy, the whole sandwich clamped to the dinghy transom.  Messy, but it turned out about as well as I had expected.  After some trimming and filling, it'll work just fine and should look good too.




While I waited for the epoxy to cure, I decided to tackle the autopilot issues with my new volt meter.  Well, the damn thing worked again the minute I turned it on and continued to work fine for the several days I was there.  The only issue was that the breaker switch for it seemed to cut out one night.  But the next day, that was fine too.  Loose connection shorting the circuit intermittently?  The other possibility is that when we were out on the water last week, I was too impatient to wait the second or two it takes for the autopilot to come up after turning the switch.  Anyway, as long as it's working, I can't trouble shoot it.  So, having bought more fluid and the bits to make a new reservoir, I decided to do a very complete and thorough bleed of the system with some help from Ron, who pushed steering buttons on the autopilot and turned the wheel repeatedly while I cracked connections and bleed points.  An hour later the steering felt much tighter.  I continued to test and crank away for the next day and a half until no more bubbles appeared in the reservoir tube.   Much less freeplay in the steering and the autopilot now was able to turn the rudder smoothly rather than unevenly as before.  One mystery remained:  after the system 'rested' for a while, the autopilot would turn the rudder lock-to-lock in six seconds two or three times, then slow down to take at least twelve seconds.  The motor winding down like the battery was going dead, but the charger was on and it had a full 14 volts the whole time.  I tried this several times with the same results.  Time to call Wil at WH to see what gives.  




September 12, 2011

It's been a busy week, filled with chores, projects, problems and a bit of fun.  At the house, I was busy keeping it in showing condition while I did some projects in the shop.  As a consequence of spending a few days on the boat last week, I decided to do a few things to make it more livable.  I had a decent mahogany dish rack that I had removed from my last boat because it had been built in so close to the underdeck that it was unusable.  By building it into Circadian's galley I would free up a couple of drawers and make access to dishware handier.  So, I refinished it and built new supports to fit it into Circadian.  I also made extensions for the outboard fuel tank's hold down brackets.  They were too short to use on the dinghy, and the P.O.'s solution was an ugly spiderweb of lines.

My friend Nick had invited me to go fishing with him on Friday, so we met up at oh-dark-thirty and headed for Lake Berryessa  to fish for kokanee salmon.  Nick is an avid and extremely knowledgeable angler, while I hardly know which end of the pole to hold.  Needless to say I learned a lot, had a lot of fun, and even caught several fish.  Because the kokanee salmon's favorite food is plankton, rather than trying to tempt it with food, you are trying to irritate it into attacking the lure.  There's a lot to it, more than I can detail here.  Besides, I promised Nick I wouldn't reveal all the secrets.





 


Saturday, it was back out to Circadian to see how well I'd done with my shop work, continue working on the autopilot, perhaps get the outboard going, and tackle some other projects on "the list."  Checking the fuel tank brackets was fast, easy and successful.  However, in the process, I discovered that the fuel pickup tube in the tank was gone.  There would be no outboard testing this week, just another task (replace the pickup tube) added to the list.



Mounting and testing the heater chimney cap guard was also fast and easy, but only partially successful.  It does of course get hot on the top, but not as hot as the chimney cap.  Perhaps more importantly, it's not the type of shape one is likely to grab for, especially with the new grab handle in place.   However, I discovered when maneuvering Circadian that it interferes with the throttle control lever and I'll need to turn it 90 degrees to provide the needed clearance.  Only four wood screws, so it's no big deal.


I installed a new ventilation fan to push cool air past the refrigerator's compressor and cooling tubing and then out the new ventilation hole in the top cover.  It was easy to wire it into the compressor fan's circuit so it comes on only when the compressor is running.  I also filled the gap between the top of the refrigerator and the top cover with expanding insulating foam.  After a couple of days of use in the heat, I was delighted with the improvement.   I would guess at least 25% less run time at a cost of only .38 amps (including the very cool blue LEDs!.  What can I say:  the fan with the LEDs was $10 cheaper than an equivalent one without.)  In the process of diving down into the innards of the frig box, I noticed that there remains significant space between the outside of the refrigerator and the inside wall of the box.  I think I can gain even more efficiency by filling that gap with foam.  By using my proven, but not patented, "foam in the trash bag" method, I think I can do it with little mess.  It should even allow the refrigerator to be removed without surgery if necessary.


 





 
Next I installed the dish rack.  It went in nicely, with minimal grinding necessary for the final fit.  Best of all, it cost me nothing:  everything, the rack, side panel, stainless screws, even the Epiphanes Rapidcoat varnish, was salvaged or leftover.





My next task was wiring up the steaming light.  That required installing a switch for it into the running lights circuit.  I was able to find a spot for the switch in the old cockpit breaker panel, and drilling a hole in the aluminum panel was no problem.  The wiring was simplified by placing the switch there, and it was also the logical place for it.  Doesn't look too bad either (although the panel itself obviously needs work).  Because the switch illuminates when in the "on" position, it's a reminder that the steaming light is on.  The wiring was relatively easy and painless, and the light worked just fine.  Inspired by my success, I finally properly secured all the loose wiring that had been dangling down from the ceiling in the main cabin since I bought Circadian.  To cap off the day, I got to check off an item from "the list."






At this point I was happy, but pooped and had nothing aboard for dinner.  The new $4.5 million ferry was out of service again, so it was a long drive to a store.  Fortunately, Manny and Mary, dockmates at Hidden Harbor came to my rescue.  They were planning on making the drive and offered to pick up something  for me.  Well, they not only did the shopping, but they cooked it all and invited me for dinner!


Another dockmate, Gregg, had helped me do a more complete job of bleeding the hydraulic steering, so Monday morning I was ready to take Circadian out again to calibrate the compass (without magnetic headsets!) and see how the autopilot performed.  At the dock, the helm definitely felt tighter, but the autopilot steering was quirky.  While in general it still took more than twelve seconds lock to lock, a couple of times, after the system had been idle for a few minutes, it did it in about six seconds.  But it would never repeat that.  Very odd. 
In any case, Ron once again offered to help me take the boat out and Barry, the harbor's resident limey, also wanted to come along.  So off we went.  We were out a couple of hours and things seemed to be going fine until just before we got back when the autopilot suddenly went dark.  Back at the dock, my efforts to troubleshoot the problem were stymied.  The depth sounder was on the same circuit as the autopilot and worked fine.  The fuse in the autopilot's Heading Electronics Box was okay.  I was also thrown for a curve when my trusty volt meter suddenly became untrustworthy.  It would read fine one minute and then show no voltage in an active circuit.  Well, at this point the frustration-to-time ratio had reached the terminal point.  Besides, the dog's legs were now hurting so much he could hardly walk.  It was definitely time to head home for some healing before heading back into the fray.