Category Archives: Boat Details

Failures Bring on Frustrating Times

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Sugar Shack has had a string of failures over the last few weeks. I cannot remember a time when I’ve been so frustrated.  

Our boat has been and continues to be an amazing vessel. 

She has safely transported us over 50,000nm across both the Atlantic and Pacific Oceans.  She is our home, our yacht, our love and I would not trade her for anything else.  We love our Catana!

However, with anything over 24 years old you have failures.  

All of this happened over the course of 2 weeks in route to Fiji from the Marshall Islands.

Double Steering Failure

As you might recall, we had a “A Double Steering Failure” when we lost our starboard steering gear box and our port rudder arm.  This rendered our starboard helm un-steerable and our port helm without a rudder. 

Makes steering a challenge, but still doable with auto pilot using the port steering gear box and the starboard rudder.

Problem: ​Starboard Steering Gear Box failed. 

Solution: We ordered new bearings and seals from Germany for both port and starboard.  They’re being sent to Fiji where we will do repairs.

Problem: Port Rudder Arm failed. 

Solution: The good news is it broke at the attachment point.  We found the one man who has the tools to weld stainless and he fixed our rudder arm! We need to weld the two pieces together at the exact correct length to reinstall the rudder arm.

Matt and I searched for a stainless welder all over Funafuti over 3 days.  We finally found the one man who has the tools and expertise.  He tack welded the two pieces together, then did some grinding, then finished the welding.  We are back in business with two rudders!

A Massive Disappointment

Port Engine Failure

Problem: Our port engine water pump had a slow leak.  We had been watching it and were prepared to replace it once we got to Fiji. However, the leak got progressively worse.  So, Matt decided to replace it in Tuvalu.

The water pump is located in front of the engine making it a challenge to access. Matt has to lean over the engine, upside down to access the pump. Many pieces and parts have to be removed including the timing belt.

Problem #2: As Matt was removing the timing belt it ripped!  Oh for the love of God!  The engine can’t run at all without a timing belt!  This is bad, very bad!

Solution: The water pump was installed, but there is nothing we can do about the timing belt.  We ordered (2) new timing belts (one for both engines) from the UK to be delivered to Fiji where we will do repairs.

More Annoying Issues

Problem:  As Matt was removing pieces from the engine to get to the water pump one of his most used sockets fell into the water.  We are in 14m depth (40′).  

We got the dive gear out and both pressure gauges had water ingress and were not readable. 

Solution:  Matt used the dive gear anyway and within 4 minutes found the socket!  Yeah.

Problem: The furler is starting to fail and is leaking.  It is still working, but we have to be gentle when using the genoa.

Solution: We ordered new bearings and seals to be sent to Fiji where we will do repairs.

Problem: The washdown pump failed.  We use this pump to hose off the boat and clean the ground tackle (with both fresh and salt water).

Solution:  Matt thought we could just take it a part, clean it and get it working.  But this 13 year old pump was done.  We will have to buy a new one.

Summary

 
We have one engine and one rudder forcing us to run between helm stations. And somehow make it to Fiji to do the repairs.
 
Good news:  
  • We can steer from the Port helm and run back to starboard to use the throttles
  • We found a stainless welder in Tuvalu (the 2nd smallest country in the world). We now have use of both rudders
  • The port engine NEW water pump is installed
  • The engine was off when the timing belt failed.
    • Would have been catastrophic if it failed with the engine on.
  • We found the socket in 14m of silty water.  New octopi will be purchased in the future
  • Matt thinks he can take the washdown pump apart, clean it, service it and get it working without a replacement.  
  • The furler still works but we have to be gentle using it.  

Trying our best to see the silver lining. We are truly blessed and know that “life happens.”  It’s just hard when it happens all at one time.

We find some joy and charm in Tuvalu – check out our last blog post.

Our blog posts run 8-10 weeks behind actual events.  The failures occurred between mid to end of March 2025.

A Double Steering Failure

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Matt and I were enjoying a lovely sail from the Marshall Islands to Kiribati.  About 55 hours into our 63 hour passage we noticed an issue with our starboard steering.  Yikes!  Our engine throttles are on starboard so we use starboard as our main helm and port as a “back up.”

The good news is that auto pilot is working ok and the port steering is working ok.  We were able to safely navigate through the Kiribati pass to the anchorage.  Matt jumped in the hole as soon as the engine cooled off.

What Type of Steering is on Sugar Shack

There are multiple types of steering on yachts: mechanical, hydraulic, electric, and electric hydraulic.  We have mechanical on our boat.

How does mechanical steering work?

The mechanical system is usually made up of a Rack-And-Pinion or Worm-And-Sector steering gear that is physically connected to the helm. When the steering wheel is rotated, this mechanical system also turns. These mechanical systems, in turn, drive a pitman arm that physically turns the wheels of the boat.

Which is the same as “Christine speak”

When you turn the starboard wheel it turns the “Steering Gear Box”. The steering gear box then turns the “Arm” which is also connected to the port steering box.  That in turn rotates our port and starboard “Rudder Arms” which turns the rudders which turns the boat.  It works the opposite way as well when you turn the port helm it turns the starboard steering.

I am sure there are more technical terms for this system, but hopefully I described it well enough for you to follow along.

What Happened?

Steering Gear Box:  We are not 100% sure what happened to the starboard steering box.  It could be age and regular wear and tear.  It also could be something else???  We tie off the wheel while at anchor to reduce movement of the boat.  Could this have been a problem??

Matt disengaged the steering box after a lot of struggle.  It is super heavy and located in an awkward position.

What we discovered was the following:

  • Water appears to have dripped from the either the compass or a seam into the gear box.  We will have to reseal the helm.
  • The bearings were shot and the balls were floating around
  • A lot of gunk was in and around the gears
  • One section of the gears was stripped

Temporary Fix

There is nothing we can do in Kiribati (where we are now) or Tuvalu (where we are going next).  But we can disconnect the starboard steering box so that we don’t do any more damage by using the port equipment.

Matt ordered (8) new bearings and (4) new seals.  It will take approximately 6-8 weeks to get to us from Germany.

What Else Happened?

A few days into our passage from Kiribati to Tuvalu we discovered another problem.  The wind had dropped to 5kts so we decided to drop the sails and motor.  Matt jumped in the engine room and  found a major problem.  The port rudder arm (tie rod) was broken at the attachment point.

You have got to be kidding!!!

We don’t know what happened, but the only way to fix it is to weld the stainless back together.  Obviously we can’t do that while underway.  Matt lashed the arm down to prevent further damage.

How Are We Able to Steer?

Auto pilot is located on the starboard helm.  He has been running great!  Auto turns the port gear box which turns the arm connecting the starboard and port helms.  The arm then turns the starboard tie rod / rudder arm which turns the starboard rudder.

Basically bypassing the two broken parts on both starboard and port.  Thank goodness for redundancy on a catamaran!

Repairs

There is not much we can do until we get to Savusavu, Fiji.  So, we are being super gentle with the boat and her steering.  Good news we have very light winds and moderate seas so there is not a lot of pressure on Auto Pilot or the rudders.

Stay tuned for repairs…

Our blog posts run 8-10 weeks behind actual live events.  We were under passage from the Marshall Islands to Kiribati, then Tuvalu, and then Fiji in mid to late April.

Be sure to read the good news about this passage here.

Boat Projects

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There is a never ending list of boat projects that need to get done.  And just as you finish one project, two more will appear.  Just like owning a house.  Matt tackled several projects while we hung out and waited in Majuro.

Anchor Shank

Our stainless steel anchor shank decided to wrap itself around some coral.  This could have happened a number of ways including strong winds, dragging, or raising the anchor.  Most likely the anchor was stuck and the swivel twisted causing too much pressure on the shank.  As you can see….it is really thick 316 Stainless Steel.  But the shank is hallow.

We have 4 shanks onboard for 2 anchors.  This shank is beyond repair and will be donated or trashed.  Comparison of good shaft to bent shaft.

We ordered an X140 from Sea Tech & Fun based out of Tunisia!  The shank comes with one hole drilled for the connecting point to the swivel as that is a universal size.  However, we had to drill the hole for the connecting point to the blade.  The shank itself is hallow. Matt drills through the top 1/4″ and then down to the bottom 1/4″ and hopes it lines up!  This requires a new, large drill bit!

Security Camera

We have had a security camera on the boat for a few years.  It’s been great and has captured some intruders who boarded our boat while we were on shore once.  But the paint on the outside has flaked off and it looks horrible.  It still works perfectly, but we need to give it some love at some point.

In the mean time, Matt purchased a higher end security camera.  This new camera illuminates the entire cockpit when it senses movement and then starts recording.  This camera captures intruders coming onboard from both port and starboard.  It also captures the entire cockpit.  The only thing missing is an audio portion with a barking dog or a menacing voice saying “intruder alert.”

Security Bars – escape Hatch

The boat has the best escape hatches!  They let in a tremendous amount of air that circulates throughout the cabin.  They are always open when we are on the boat.  Our concern was that these can pose a security risk.  It would be very easy for an adult to climb through the window.  So, Matt devised this super strong security bar made of carbon fiber.  It took some ingenuity to install it while still giving us access to open and close the hatch.  I would prefer to put a secondary bar perpendicular to the ocean but that would really obscure our view.

Bilge Pump – Float Switch

We have bilges which collect water to protect the boat.  The bilge will fill up first before it becomes a problem.  Inside each bilge is a bilge pump that is has a float switch.  When the bilge fills with water the switch activates the alarm and the pump to pump out the water.  Matt noticed that one of our float switches was broken.  He lifted it and it no longer activated the alarm or the pump.  That is not good!  Especially considering we are leaving the boat unattended for 2 weeks.  Luckily, Matt was able to repair it.  But we will get 4 new float switches back in the states as these are original to the boat (24 years young!)

Bow Speakers

Our amazing WetSounds Rev9 bow speakers take a beating while we are under passage.  They often get soaked with salt water.  Yet, they continue to produce great sounds.  Lately however we noticed the starboard bow speaker was not producing good sounds.  Matt took it apart and found them corroded and covered in salt (me being sheepish now).  So, we replaced some of the innards and now they sound just like new! Here are the old and new side by side.

VHF Replacement

Our B&G V90 (handset H50) had been giving us problems and was not transmitting properly.  In addition, the handset cable starting falling part (see arrows).  We finally replaced it with an ICOM 510BB (handset HM195 GB).  It took Matt several hours to pull out the old gear and install the new gear.  Now we seem to be transmitting well (both near and far).

Cover Photo:  Not really related to boat projects, but a great image of two locals using a canoe to transport (2) 50-gallong drums!

Our blog posts run 4-6 weeks behind actual live events.  Matt worked on these boat projects during the months of February and March while we were in Majuro.

In our last blog post we spend a day at the Alele Museum – check it out!