First sail of the season and a few more projects

I was able to get the engine back in running order with a bit of effort this past week. 
At first I thought I would be able to patch the cracked exhaust elbow, but after cleaning the area in preparation for the patch, the cracked opened up quite a bit.  I ended up ordering a new one.  Thankfully this part is still available. 
Cracked exhaust elbow before cleaning
Crack got a bit bigger after cleaning
I was worried that removing the old cracked rusted exhaust elbow from the part is was attached to (silencer) would be an issue so I brought it to work.
After soaking it in penetrating oil and adding a little heat, they came apart ok.
This looked like trouble at first
 
After penetrating oil and a little heat
I soaked all the parts I had removed with the cracked exhaust elbow in CLR overnight, wire bushed them, bead blasted them, and then painted them.
They look as good as new.
Shiny!
Everything reassembled without incident and the engine is running great.
Reassembled and running
 
I also finished the plumbing connections for the new electric flush toilet and did the electrical wiring.  Other than a leaking (small) anti-siphon fitting for the fresh water line, it all works as planned.
All the plumbing is connected and working
Fresh water plumbing.
The thru-hull fitting is on the right connected to a water strainer before the pressure pump.
Switch bank installed and working.
It includes a switch for power, one for auto flush, and a third for manual fill and a manual flush
 
My brother and I also installed the electrical connector for the Auto-Pilot.  It’s not wired yet, but will be ready for the next sail.
Auto-Pilot connector installed in the cockpit
 
My brother and I also went for the first
sail of the 2013 season.

It was a bit chilly at 48 degrees and cloudy when we left the harbor at 3:30 with a moderate breeze at 10 knots.  Our high speed was 5.0 knots, but the wind died down to 2-3 knots an hour later and we weren’t going anywhere quickly at that point.  Still, it was good to get out on the water.

 
During the off season I bought a new (for me) “Hank on” sail bag for the jib.  Now we can leave the jib in place on the forward stay and the jib sheets attached when we are done sailing.  It will make for a faster get away when leaving for a sail and stowing everything afterwards.
New “Hank on” sail bag for the jib

Back in the water for the 2013 season and winter projects

A friend from work and I move the boat from the boat yard to the marina yesterday after work.  We have a new slip this year.  Last year we took what was available in terms of a slip.
It was a 40 foot slip for our 29 foot boat.  The new slip is a 30 foot slip.  I discovered last night there is a big difference in coming into a 30 foot slip with a 29 foot boat as compared to a 40 foot slip.  The 30 foot slip doesn’t leave room to maneuver.  It is a tight fit.

Thanks Dad’s new slip
Tight fit in the slip

I also discovered a crack in the engine’s “mixing exhaust elbow”.  This is the pipe where the exhaust and cooling water come together before exiting out the back of the boat.  So during our trip to the marina, all the cooling water and exhaust came out the crack and not the back of the boat.  It made the engine compartment a bit wet.

Crack in Exhaust elbow

Over the winter, we did several projects and ebay became my new friend.
Unlike last year’s March when the average temperature was 50 degrees and we had a week in the 80’s, this year’s March had an average temperature of 30 degrees.  It finally got into the mid 40s the last couple days of the month so my brother and I took the opportunity to remove the tarp and breakdown the frame.   We match marked each piece of the frame so we will be able to get it back together in the fall without too much trouble.

We did miss drilling and screwing one of the 45 degree fittings on the frame and in January it separated and then shifted the whole frame causing the back to open up and a couple tears in the tarp.  We fixed it and it was fine afterwards.  In March one of the other 45 degree fittings broke (it had been properly drilled and screwed) but didn’t cause a problem with the tarp.  Since it was so close to the end of the winter season I didn’t bother making a repair. All in all the frame/tarp survived the winter fairly well.

Tarp after the Winter

I bought an electric flush toilet on ebay.  It was a mfg rep’s demo and is in perfect shape.  The manual pump on the old toilet had a crack and I got the new one for less than what replacement parts for the old one cost.  I removed the old toilet, removed and replaced the old thru-hull fitting for the water intake, capped the overboard discharge thru-hull fitting, took out the old flooring, hoses and bladder style holding tank.  Cleaned and painted the hull in the head area, fabricated a new floor for the new toilet from “King Starboard” and installed new hoses and a hard sided holding tank.  Still need to do the final connections from the water intake to the pump and then the toilet.

Old head area
New head area
Old bladder holding tank
New holding tank

Under each of settee berths in the cabin was a 35 gallon stainless steel water tank.  These were original pieces of the boat and at over 45 years old I was not intending to ever drink water that had been inside these things.  I removed them and am planning to make this a storage area at some point.

Removing the old water tanks

In the cockpit of the boat is a panel with indicator lights for low oil pressure, water temperature and alternator charging.  Two (2) of the indicator lights had broken lenses and there are two (2) larger holes in the panel for non-existent gauges.  These holes had hole plugs in place, but they were cracked and would fall out easily and frequently.  I removed the panel, painted it, bought new hole plugs and bought new indicator lights. Unfortunately, the holes in the panel for the indicator lights are 5/8”
diameter and the largest indicator lights I could find are ¼” diameter.  So I bought  5/8” holes plugs and drilled them to mount the ¼” lights.  Also made labels for each indicator light.

Cockpit engine panel before and after

My dad had rigged the boat for single handed sailing by removing  the mast winches and cleats for the mainsail  and jib halyards and mounting them on top of the cabin so he could raise and lower the sails from the cockpit.  I bought and installed used winches and rope clutches on eBay to update the rigging.  I cleaned and re-greased them before installing them.  I also cleaned and re-greased the jib winches and  bought new line on eBay to replace the main sail halyard.

Old rigging
Winches before and after cleaning
Newly cleaned winch during installation
New rigging with rope clutches and winches.

Before fabricating the tarp frame in the fall, my brother and I removed the lifeline stanchions and their bases from the deck.  Several of the stanchions were bent and the guys at work straightened and polished them for me.  They also cleaned up the stanchion bases by bead blasted them.  They are looking like new now.

Stanchion before and after
Stanchion bases before and after

I had to cut the life lines in order to remove them from the stanchions, so we had new life lines fabricated and changed the design slightly with a threaded gate eye at the most aft stanchion.  This way the life lines and be removed without cutting and they don’t become too loose and useless when the gate is
open.

New life line’s Swivel Gate Eyes

The bow and stern pulpits were also bent.  I think the mast resting across them when the boat was hauled from Maryland bounced up and down and bent them.  I tried to straighten them myself, but didn’t have the proper tools to do it.  So I found an auto body guy who was able to do a good job improving them.  They are still not perfectly straight, but are a lot better than before.

We also painted the cockpit area.  Last year we primed, but we never got around to painting it.

Painting the cockpt

12-September-2012 – Stern Seats

Many newer sailboats have stern seats.  My brother and I thought it would be good for us to also have some.  It would provide additional seating room and make for a more comfortable and less crowded cockpit area.  We decided we didn’t need the davits and would use the same mounting holes so as not to add any additional holes in the deck.

Davits Removed
Davits Removed

I visited Kendore Marine Supply and found a couple of pieces of “King Starboard” that would do the trick for the seats.

I brought an old rectangular milk crate to the boat to use as a base to help determine what the height of the stern seats should be.  The milk crate has 3 different dimensions and we found that we liked the one that would put the top of the seat 13” above the deck.

Using milk crate to help determine height
Using milk crate to help determine height
Using milk crate to help determine height
Using milk crate to help determine height

I made a couple wooden bases out of plywood and 2x4s and brought them to the boat to get the exact dimensions needed for the design of the stern seat bases.

Wooden base mockups
Wooden base mockups

Once I figured out the final base design requirements (dimensions and angles) I drew it up using AutoCAD and the guys at work fabricated and welded the stainless steel pieces.

AutoCAD Design
AutoCAD Design
AutoCAD Design
AutoCAD Design

Last night after work my brother and I went up to the boat and installed them.

New stern seat bases installed
New stern seat bases installed
New stern seats
New stern seats
New stern seats
New stern seats

We still have a couple things to do before completing the project.  We still need to countersink the bolts holding the seats to the base and install the cup holders I bought for the seats.

29-February-2012 – She arrives!

After getting the call from Jan that the boat was about an hour from arriving, I left work and made it to the boat yard about 15 minutes before they arrived. The weather cooperated with sunny skies and 50 degree temps. Not bad for the end of February!

She Arrives
She Arrives

Unloading the boat from the trailer and setting it on the cradle went like clockwork.  I was very impressed with the guys at Larsen.  They were very efficient.  I guess they have done this a few times!

In the cradle
In the cradle

With the boat safely on the cradle and in its assigned location at the yard I went back to work  I did not have a chance to get on the boat and take a look around.

In the cradle
In the cradle

Sept – 2011 through Feb 2012 – Planning to be boat owners

My brother and I did a lot of investigating.  There are several places from, Hammond, IN to Racine, WI where we could keep the boat.  We visited them all and decided on Waukegan, IL.  The Waukegan Harbor Marina is nice, the travel time from home to the Marina is exactly an hour, the slip price is good and the Larsen Marine boat yard is right next door.

We still needed to find a way to haul the boat from Maryland to Waukegan and I placed an ad on UShip.com initially in October 2011.  Didn’t get any bids.  I relisted in early February 2012 and received 2 bids and accepted one of them from Sea Wise Inc.  The husband and wife team, Ed and Jan, at Sea Wise made the entire process of getting the boat from Maryland to Waukegan a painless experience.  Jan communicated constantly on the current status of the process and when Ed and the boat were in transit, she kept me up to date on their location over the 2 days it took to get to Waukegan.  I asked her to let me know when they were about an hour from arriving at the Larsen Marine boat yard.  She did and I was able to be there when Ed and the boat arrived.

31-August-2011 – Growing Up in Maryland

Growing up in Maryland, my family (dad, uncle, grandfather, siblings) were sailors on the Chesapeake Bay, a beautiful body of water with over 5,000 miles of shoreline and many fun places to visit when sailing.  My Uncle and grandfather had a 35 foot sailboat that they owned for personal use and also chartered.  My dad had a 25 foot that we was solely for personal use.  Our summers were spent sailing almost every weekend and then we took longer trips when Dad would take his vacation days.  I enjoyed that a lot.

As occurs to all of us, as we grow up and get older, “life happens”.  Parents’ divorce, remarriages, step-familys etc.  I moved from Maryland to Illinois in 1975 during my freshman year in high school with my mom, brother and step-dad.  Then high school, college, my own marriage and children.

The first few years after moving to Illinois, my brother and I would spend a good part of our summers visiting our dad in Maryland and still sailed a lot.  After about 1978 though, with the start of my adult life, trips back to Maryland became fewer and sailing during those trips rarely happened.

Dad of course continued to sail and even got a bigger boat in 1992, a Contest 29 built by Conyplex B.V., a Dutch company.  S.V. Dutch Treat

Dutch Treat Contest 29 - July 2004
S.V. Dutch Treat  – Contest 29 – July 2004