Showing posts with label autopilot installation. Show all posts
Showing posts with label autopilot installation. Show all posts

December 1, 2018

Got a very unusual (for this time of year) rainstorm this week that brought more than three inches of rain in one day.  That brought clouds, which brought some nice sunrises and sunsets.  And despite coming down with a sore throat and cold, I got the hydraulic steering working again and started the installation of the new Simrad autopilot.  Ahh, the glamour of yachting!


Around La Cruz de Huanacaxtle


Can't let a little rain stop you from setting up your
mobile restaurant in the middle of a street corner.

Some folks like living, or at least parking, on the edge.

Sailboat on the horizon

Low tide on the beach by the marina

Beach sunset

Sunrise from Circadian

Looking southeast, it's actually a sunset!

Sunset at low tide

Damned grackles ain't got no couth!

Could be worse.  Look closely and you will see 
there are HUNDREDS of white-collared
seed-eaters on these wires.

Boat Work


Starting in on the new autopilot installation.
Always unnerving to cut big holes in the boat.
Measure three times; cut once?

Gulp!  Here goes.....

Nice, clean cut-out for the new Simrad autopilot
display and control.

Perfect fit

Protective cover on

Rebuilt base painted and ready for remounting the
hydraulic steering cylinder.

In order to make absolutely sure I didn't go through the
bottom of the hull, I used screws of different lengths
and carefully marked the drill bits to accommodate 
the amount of clearance.

Base remounted

Notice the rudder stop crossmember has been removed
to make installation easier.

Hydraulic cylinder remounted.

Hoses connected, rudder stop crossmember re-installed.

New Simrad autopilot motor/pump mounted 
and hoses connected.

Now the messy part:  filling the system with 
hydraulic fluid and then bleeding the air
out of it.  This is the set-up I devised 
last time I had to bleed the system.  It 
worked well, with minimum mess.

Some oil spillage is inevitable when bleeding
the system, so I prepared for it with oil-
absorbent pads.  After MANY repeated
turns of the wheel and some help from Tod,
we got it done.  It was good to at least have
manual steering back.

August 22, 2011

I continued to focus on the autopilot installation this week, and with a couple of days on Circadian, I was able to make significant progress. Earlier, at home in the shop, I had turned a handful of old synthetic wine corks on the drill press to use as plugs when I disassembled the old hydraulic lines from the original autopilot pump. With clearing skies, it had gotten hot again, and the most interesting scenic on the drive to Hidden Harbor was a group of clouds with unusual mares tails hanging down from their centers.




Once on board, the first order of business was to crawl down into "The Hole" or aft lazarette to remove the old hydraulic pump and plug the lines while hoping not to create a hydraulic fluid spill reminiscent of the Exxon Valdez.

I managed to do it without too much of a mess, since I had my cork stoppers ready and the inside of the hull in the area was covered with layers of rags. Of course most of what did spill ended up right in my lap. With the remnants of the old system cleared out, mounting the new WH Hydraulic PowerPack (1/4 hp motor and hydraulic pump) was pretty straightforward: four SS lag screws in the plywood shelf. Mounting the new controller behind the pump was equally simple. Running the cable between the motor controller and the Heading Electronics Box was accomplished with the usual cursing, crawling and contortions.

At that point it was definitely too hot to continue work in "The Hole," so I took a break and did some minor clean-up and socializing with dockmates. The next morning I tackled the installation of the Rudder Angle Transmitter, dubbed the "RAT" by WH. Having now experienced how tricky it can be to get it right, I can understand. What makes it tough is that the pivot arm on the RAT must remain parallel to the rudder arm in all dimensions and angles of rotation and align with the shaft center marks when the rudder is centered. I'll spare you the details, but to give you an idea of what's involved, the manual includes three pages of text and four diagrams covering just the RAT installation. My particular installation was complicated by the fact that Circadian's rudder arm faces aft rather than the usual forward, and it's angled downward about 20 degrees. It took me at least three attempts, but I finally got it lined up. Wiring it up was comparatively simple, but I won't be sure I've got the directionality (polarity) right until I test it. At this point the autopilot installation had gone as far as it could without additional supplies. I needed heavier cable than I had on hand to handle the 25 amps that the big motor might draw. I ordered it from genuinedealz.com, the same company that supplied the big cable for the windlass installation. Twenty five feet of two conductor #10 tinned marine grade was under $30 (with free shipping) compared to Worst Marine's catalogue price of $3.25 per foot. I also needed to get new hydraulic hoses made to plumb the new pump into the steering system, but that would have to wait until I was back in town.



It was with considerable relief that turned my attention to the less strenuous and more fun project of organizing stowage in the cockpit lazarettes. These had been gutted and turned into engine room access hatches by the P.O. Convenient, but a significant loss of important storage capacity. I wanted to preserve access but still be able to provide easily removable stowage for critical items. I had previously picked up a 30 ft roll of 1 1/2 inch-wide Velcro One Wrap for $20 at Home Depot (compare to WM price of $7 for 3 straps 1 inch wide by less than one foot long) with the idea of using it to secure PFDs to the underside of the lazarette lids. Strong enough to hold them in place, but self-releasing if torn off in a panic. I had also bought a couple of 5 gallon plastic buckets with twist-off air-tight lids at TAP Plastics. One would contain abandon ship gear, the other dry dog food. The idea was to suspend them in the port side lazarette by the handles using carabineers and u-bolts so that they were secure, but easily and quickly removable. It took a couple of hours to install the SS u-bolts (also obtained at Home Depot for half the WM price, and adequate for this non-critical application), but it worked so well that I added a third to hold a smaller bucket for my bbq charcoal supply. I will need to complete the set-up by adding bungee cord around the buckets to keep them from banging around when the boat moves. It all worked out great, with the PFDs now handy, but out of the way, and not interfering with anything. The starboard side lazarette remains open for engine room access. It's where the big old AC generator used to be (see older blogs for the removal saga), and where a small workbench will eventually be built.



Finally, I cleared away a pile of gear that had accumulated in front of the nav station to the left of the helm. Amazingly, at the bottom of the pile I discovered the mysteriously vanished teak steering wheel hub I had made, lost, and remade months ago. Ah well.


I wanted to insert a teak grate over the recessed area at the foot of the nav station, since it was definitely a potential ankle-breaker. And since I had salvaged a suitable (albeit oil-soaked) grate from the aft lazarette, I thought I'd make some measurements so I could reshape it at home later. All that remained was the usual pack-up and clean-up, and I was headed home.

August 15, 2011

Last week I completed the last of the preparations for putting the house on the market, and was able to dedicate two days to work on Circadian. With the house "untouchable," I'll be spending more time on Circadian. In the meantime, things are a bit chaotic because I'm neither here nor there. As every sailor knows, it's OK to stand on the dock or step onto the boat, but you can get into real trouble by standing with one foot on the boat and the other on shore.




I've begun bringing more things for living aboard, but it's a continuing challenge to organize and find the right place for all the stuff since the boat is in the middle of restoration and the aft cabin is stuffed chock-a-block with tools and gear. Because of the sorry state of many of the lockers, drawers and cabinets, I often have to do some refurbishing or modifications before I can use them. Not surprisingly, then, one of my goals for the week was to convert the now-inaccessible drawer under the new v-berth extension into a locker with hinged front so it can be used. Once that was accomplished, I wanted to get started on the installation of the new WH Autopilot, which they say is at least a three-day job.





On one of my trips to the boat, I managed to bring my kayak, which features a clear plastic center section for underwater viewing, down to Circadian. I covered it and secured it in place on the cabin top after rearranging the spare anchor beneath it so it wouldn't foul the genoa sheets.




During one of my days at the house, used the shop to modify the v-berth drawer. First, I cut the drawerfront off the box.



Next, I cut the drawerfront lengthwise so that I would have a lower piece from which to hinge the main section of what would become the door.



I spent about twenty minutes carefully setting up the table saw to cut recesses for the hinges on both pieces of the drawer front cum door. It was time well-spent as the cutting itself was quick as well as perfectly accurate and symmetrical.





I even had some time left to lay on a coat of varnish on both the new locker front and one of the other under-berth drawers that was unfinished. The most painful part of the whole process was having to pay $25 for a pair of stainless steel hinges at Worst Marine, since I didn't have the time to order them elsewhere.






The next morning, I headed to Hidden Harbor to install the newly converted drawer. As usual, it was a nice warm day with some interesting wispy mares tail clouds on the horizon. A bright new sunflower greeted me at the entrance gate when I arrived.



Once onboard, my first step was to screw down the old drawer box to form the new locker space.





Next, I screwed the door made from the drawerfront into place. Once I cover the countersunk screws with teak bungs, it will look great. I also need to add an elbow catch so that the door can't open accidentally. In the meantime, it's ready for use and provides easy access to stowage even with the berth extension in place. Speaking of which, I have given the paper pattern I made last week to an upholsterer to get the new cushions made. It will likely take at least a month, so I'll have to be patient.






With my new locker space completed, I started on the autopilot installation. That is a priority because it must be installed and tested within 30 days from purchase to retain the warranty.




The WH Autopilot consists of several components: the pilothouse controller, used to set and use the autopilot underway, a fluxgate compass to tell the computer the boat's heading, a heading electronics box, which is the main cable junction box, a rudder angle transmitter that tells the computer the actual rudder angle, a 1/4 hp electric motor to power the hydraulic pump, an electronic motor controller, a hydraulic pump that must be plumbed into the existing hydraulic steering, and various cables, valves and fittings to connect all the components.




The first phase of the installation process was determining where each of the key components would be mounted. The locations for some, such as the pilothouse control, the rudder angle transmitter, and the hydraulics, were largely dictated by necessity. Locations for the remaining components were determined by maximum cable lengths, accessibility, protection from weather, and, in the case of the compass, a series of geometrical and magnetic requirements. It was a demanding process that took a lot of measuring, remeasuring, and head-scratching. So, I started with what I thought would be the easiest part: mounting the pilothouse control. I wanted that easily viewed and reached from the helm, and visually contiguous with the other helm instruments if possible. The obvious spot was next to the instrument panel. HOWEVER, because of the limited length of the cable that connected it to the heading electronics box, I wasn't sure if it would be possible, given my options for where the heading electronics box could be located. I was going to have to mount the heading electronics box first, then see how close I could come to getting the pilothouse controller where I wanted it once the cable was connected. The heading electronics box also had to be within the 30 ft cable length of the compass. The compass, in turn, had to be located as close as possible to the boat's center of gravity and at least 30 inches away from any sources of variable magnetic fields, which include everything from radios and the engine to literally the galley sink. I eventually determined that the best compromise for locating the compass was in the corner of one of the lockers under the settee. It was on the boat's centerline, reasonably close to the center of gravity, and away from sources of magnetic influence, with the exception of a bunch of old tin cans of food in the locker that can easily be relocated and replaced with non-ferrous stores. So, now I had to mount the compass and run the cable to the planned location of the heading electronics box to sure it would reach. I had to tear up the saloon and drill a lot of holes to do it, but it was a happy conclusion in the end: the cable was long enough. So, now I could mount the heading electronics box and run the cable to the pilothouse control to see where I would be able to mount that. That too required drilling holes and performing the usual contortions to run the cable. But again, it was a happy result and I was able to mount the pilothouse control right where I wanted it.

















Although there is still a lot of work to go before the autopilot installation is complete, I was happy with what I had accomplished. I cleaned up the mess, called it a day and headed back to the house.