Category Archives: Repairs

Drama on the high seas

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First and foremost everything is fine on board, we are continuing on toward Fiji as planned still with a stop in Tuvalu.

We left Majuro bound for Fiji with 2 stops along the way, Kiribati and Tuvalu.  Its the end of cyclone season, Yippie, except for the one that just popped up between Vanuatu and is heading toward New Zealand.  We are heading to “Bula” country, home of friendly people and kava ceremonies. 

When we left the Marshall Islands we had 2 steering helms, 2 rudders, 1 auto pilot and 2 souls capable of steering the boat with any of those.  And we have an emergency tiller too, in case everything goes pear shaped.  Let me say, we have had some “challenges” on this passage south. 

First arriving Kiribati, one of the steering boxes on the starboard side decided 24 years was enough, and demanded attention.   One its bearings on the inside the steering gears rusted through and burst into pieces.  One steering station down. Now we can no longer steer the boat from the starboard helm, and that is also where the gas pedal is.   So picture a clown car with the clowns carrying around the steering wheel, yet the car won’t turn. Turn as you might the steering wheel, helm, just spins indefinitely.   To actually turn, you have to run to the other side of the drivers end clown car to steer and run back to give it gas or slow down.  What can go wrong?  🙂  The clowns always make it work, right?   I actually removed the steering gear (red below) where the bearings disintegrated, so that the pieces and wobbly gear wouldn’t lock up the steering completely.  So whew,  order bearings to repair and head off to Tuvalu.  Not ideal but we have 2 of everything, part of being a catamaran.

Left Kiribati bound for Tuvalu.

The sail started out as champagne sailing doing great speeds and making short work of 700 miles we were making toward Tuvalu. It devolved a bit into prosecco sailing when the speeds dropped a bit, but still great fun.   Day 3 the squalls of the ITCZ (convergence zone between north and south hemispheres), quick wind shifts and gusts made for some exciting times.  Nothing out of the normal for this part of the pacific crossing the equator and the convergence zones.   When the wind went too light and on the nose, it was time to check the engine fluids before starting and to spot any potential issues.  I found the port rudder “control arm” broke at some point, probably during one of those pesky 30kt squalls.  The ones that steel your perfect wind and force you off course.  Thinking back, the broken bit might explain why it took longer than normal to turn downwind to run in the storm.  So the port rudder is down till we find a stainless welder.  Its lashed to the central position now, its just not wobbling too and fro willy nilly, and getting a free ride.

So for those keeping count, we have 1 working steering helm station (port), 1 working rudder (starboard), 1 auto pilot(starboard), and 2 less than pleased souls on board.   And of course the emergency tiller when all else fails.    So now we still use the gas pedal on the starboard side, run to port side to steer, the steering rudder is actually on the starboard side.   Got it?  A bit complicated but we are still trucking along, albeit a bit more conservatively till we arrive Fiji and work on getting cold beer to tackle fixing the steering project.

Is it Fiji that doesn’t like our steering?  2 years ago, one of our rudders vanished on the way to Fiji.  This year, other steering components are making their voices heard. 

275nm to Tuvalu, then another 500ish to Fiji.. we will get there!

Final Touches on Sugar Shack

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There were just a few more final touches that we wanted to make on our boat.  We still had a lot of canvas projects and we needed to replace our bathroom accessories in our two heads (bathrooms for my landlubber friends).  The bathroom accessory update is on the second half of this blog post – scroll all the way down.

Matt and I were so excited to buy a second hand LSZ1 Sailrite machine from our friend Chris.  But then fifty million projects took priority over our sewing projects and it sat for several months unused.  We finally broke it out to learn how to use it.  We decided to start with a vinyl cockpit table cover (to better protect the teak) and it was a good first attempt.  Then the sailrite sat for several more months as we focused on more important boat repairs and upgrades.  That was the final straw. We decided to ask Kim from Masterpieces in Canvas for some help with our canvas creations.

Here is a list of “final” projects:

  • (2) Cockpit table covers (1-vinyl for Matt’s work bench & 1-Salueda for guests)
  • (2) Aft cushions to go over line the bins and around the wenches on the transom
  • Redo our exterior cushion covers in a darker, vinyl fabric
  • (2) Sets of 3 pockets (mounted on the aft of the boat for storage)
  • (2) Recycle bags
  • (1) Remote wench control bag
  • Cover for our Man Over Board Horseshoe

These projects are not urgent and are not necessarily needed.  However, all of the pieces are old, ratty, and in need of a refresh or make over.

Transom Seating

Our transom spans across the back of the boat.  This is where we store our lines and where we have our working winches.  However, inevitably, we have people over and they always sit on the hard, uncomfortable fiberglass.  And if you sit over the line holders your rear end sinks into the holes.  We have wanted to add seat cushions here since we bought the boat – 13 years ago!

When we bought Sugar Shack in Turkey, we replaced all of the interior and exterior cushions.  We saved the outside foam (from the cushions) because we thought one day we might use them for the transom seating.  I will be honest, I thought we would use them a lot sooner than 13 years!  But here we are doing them now.

Matt cut the foam around the wenches, pad eyes, and stanchions.

Then we handed them off to Kim to cover.  This is more than a “final touch” and we are so excited to finally have this project done!

Cockpit Pockets

The boat came with these nifty pockets in the cockpit which collect all sorts of junk and treasures.  Spare lines, small tools, cleaning supplies, bungee, SUP fins, etc…

The stitching is coming out, the bungee is dead and they are just looking tired overall. Matt has wanted to design them a little differently so that the bungee can be more easily replaced.  

Additional Bags

We have several recycling bags where we put glass, plastic, aluminum, and cardboard.  In addition, we put smelly things that might stink up the house.  We also have a small bag that holds the main wench remote holder.  All functional, but need replacing.

The new recycle bags are just as big and wonderful.

Line Bags

We keep our main sheets inside two bags that hang off the life line off the transom.  They came with the boat, so they are at least 13+ years old.  The bags are functional, but too big for the space and we are often fidgeting with them.  Plus the fabric is torn and they are just ready to be replaced. 

We were going to ask Kim to remake them, but we ended up finding store bought ones Ronstan Line Tail Bags (large-RF3912) for a very reasonable price.  The final price with tax and shipping was $68 per bag.

The new line bags are smaller and far more functional.

Table Cloth Covers

We currently have a gray vinyl cover over our beautiful teak table.  It is our work cover that Matt uses when he works on projects and it gets super dirty.  We decided to make a dark vinyl cover and a nice salueda cover for when guests come over.  So, one will be a working cover and one an every day cover.  Kim made this awesome velcro piece underneath to keep the cover on during high winds.

Exterior Cushion Covers

We really do love the new light gray salueda exterior cushions.  However, they show dirt so easy and they do not clean as well as we had expected.  As people sit down, the back of their legs rub against the side panel and crease (seam where the top and side panel are sewn) leaving dirty marks that just don’t come out.  This just after a few months of use.  So, we decided to recover them in a dark gray vinyl that does not look or feel like vinyl!  We are hoping this will be our final recover project.

The new cushion covers turned our really nicely.  We are hoping we have better luck with these without “sticking” too much.  This is a nice touch to the boat and really looks classy.

More Sun Shades

We love, love, love our new cockpit enclosure.  However, we noticed that our sunshades needed to be expanded to cover the corner areas.  We have a giant sunshade off the transom and one for each side.  But there is a giant triangle of space between the side and the back that needed to be covered so we had Kim make us corner sun shades.  This should be the final “shade” project for the cockpit.

Man Over Board Cover

Our man over board cover was looking incredibly bad.  So bad that I did not even take a photo of it before it was tossed.  But we have a new one and it looks bright and bold!

Rail Protectors

As you know, I painstakingly varnished 90% of the exterior wood while we were on the hard.  So, when I saw our jib sheets rubbing on the cabin top hand rails I about flipped my lid.  I immediately went about making rail protectors so the jib sheets won’t ruin my varnish!

Just when you think you are done, you find more things to update and beautify.  Man we need to get out of New Zealand as it is costing us a fortune.  Well can’t really blame NZ as we’ve needed to do these updates for some time now.  We add a few more final touches to our beautiful home.

Bathroom Accessories

We have two heads (bathrooms).  In each head we have hooks, cup holders, toilet paper holders, dish holders, and towel racks.  None of these pieces were stainless steel and they have since turned green, spotted, pitted, and turned icky in general.

Matt and I searched all over New Zealand and the U.S. for 316 stainless bath accessories.  It is a lot harder than you think!  We found 304 and stainless plated but nothing else in NZ or the US.  Until we stumbled across Drench in the U.K.  We found all of the pieces we needed in 316 Stainless Steel. Hopefully these beauties will last us a life time!

And the new bath accessories in the port bathroom:

It appears starboard bath accessories are worse off than port which could be because we leave our escape hatch open and the salt air gets to these pieces more frequently.  Perhaps, maybe they are just 23 years old and tired?

And Starboard bath accessories:

These updates make me so very happy!  

Our blog posts run 10-12 weeks behind actual live events.  This blog took place during the the months of March and April.  We remove part of our standing rigging to do repairs – check it out here.

Fine Tuning the Rig

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Last season (2023) we purchased brand new North 3Di sails Tour Ultra X Sails.  However, we were having a few issues with our Genoa so we we had Roger at North Whangarei do an inspection and repair. During this repair we noticed some marks on the luff of the Genoa which indicates there might be a problem with our forestay, part of our standing rig.

See “Back in the Boatyard” for the reason why we had North do an inspection on the Genoa.  During the inspection, Roger pointed out several areas of concern.  There are black marks on the luff which indicate a potential problem with the forestay.

So, we contact Matthew at Whangarei Spars and Rigging and ask him to come inspect our rig, forestay, and furler. (For convenience, I refer to Matthew at Spars Rigging as Matthew and my Matt as Matt).

First, Matt ties our two spin halyards to each bow to secure the mast.  Then Matthew uses a ginormous 24″ wrench to loosen our side stays which will allow us to remove the forestay. Then Matthew removes the furler and secures it to the bow so it doesn’t flap around.

We send Matthew up the mast to loosen the top of the forestay.

Matt slowly releases the halyard holding the top of the forestay as I direct it away from the boat and Matthew gently places it on the grass.  It is really long at 16-17m and surprisingly heavy.

Disassembly and Evaluation

We have 9 foils, 8 joiners, and 12mm rod making up the forestay which holds our Genoa sail (or jib) and tensions the front of the mast.  A joiner is used when two foils meet and each joiner has 4 tiny screws.

Some of the screws are stripped and the men have to use a heat gun to loosen them enough for removal.  At each junction of the foils are joiners which are part aluminum and plastic.  Four of our joiners will need to be replaced as they are worn out.

While we had everything down and easily accessible, I take the opportunity to clean the stainless, remaining foils, and 12mm rod.

Repairs

Matthew replaces two of the foils and 4 joiners.  He also replaced the bearing in the furler.  Putting the forestay back together took both Matt and Matthew several hours.  You have to line up the foil just right to get it on the rod, then the screw holes of the foil have to align with the screw holes of the joiners.  

Matthew uses 4000UV glue to ensure the older joiners do not slip or move. He is able to just tighten the new joiners so that they won’t move.  Each screw has loctite applied before being inserted (this will prevent them from shaking out).

The top bearing was fine and did not need to be replaced.  The bottom bear was replaced.

Installing the Rig

Once the forestay was back together, they tested it to make sure the sail could be raised and lowered smoothly.   Everything  worked well!  Next, we slowly raise the forestay to the top of the mast and fit it back to the boat.  It took a lot of effort to get it set.  We even had to use a dynema line and ratchet attached to Matthew’s truck to pull it down and tension it.  

After it was all set, Matthew tensioned the side stays.  I asked him about a rigging survey and he said our rig is in really good condition. Despite it being 8 years old.  Plus we have 4 rods which don’t show wear unless there is a broken strand and we certainly don’t have any of those!

Our blog posts run 10-12 weeks behind actual live events.  The events from this blog post occurred at Norsand Boatyard in early May.  Did you read about the Boatyard Projects we did before leave?