Life on the Hard: Boatyard Projects

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We haul out Sugar Shack at Norsand Boatyard to complete lots and lots of boat projects.  The plan was to be “on the hard” for 5-6 weeks but a lot of projects have to be done in sequential order and cannot be done simultaneously.  We started booking contractors and work back in May to ensure that we could get all of the work done and be back in the water before Christmas.  Several blog posts will come out about this journey.

Last season in New Zealand we were able to complete a lot of upgrades, maintenance jobs, repairs, and a few miscellaneous projects.  We were tied to the dock at Town Basin Marina for almost 8 months where we upgraded to lithium batteries, repaired our salon window seals, replaced our main sail and genoa, replaced our dinghy and dinghy chaps, had a new cockpit enclosure made, new interior and exterior fabric for our cushions, new ceiling panels, new LED light fixtures, and new stainless counter tops and sink.  It was a lot!  (to read more about these upgrades, search our website for the specific blog post or click on the above links.

Hauling out

Hauling out and splashing always makes my heart race.  So many things can go wrong and yet we’ve been blessed with excellent workers at each yard.  We had a late haul out because we had to wait for high tide which was 4:00pm on our scheduled date.  We arrived and found the dock empty (which evidently was not normal).  The slipway manager was busy swapping trailers and we came in a smidge early so lucky for us another cruiser met us at the jetty to grab our lines. (top photo).  I was afraid I’d have to prove my non-existent Texas skills by lassoing the pilon.

Norsand Jetty

Norsand Jetty

Kevin, the slipway manager and Shane arrive and slowly walk Sugar Shack down the slip toward the ramp.  Another two workers showed up to toss us lines for the starboard side.  Once secured, Kevin rows a dinghy out to measure the exact placement of the trailer.

They use a large tractor to push the trailer into the water.  It has to be lined up right down the center of the boat.

They expertly manuever the trailer under our boat, without incident.  Once the trailer is in place, Kevin rows his boat out again to use the trailer’s controllers to set the supports on our bulk heads (the strongest part of the boat).  It is a slow, tediuous process, but we don’t rush them.   Slow is pro!

Coming Out of the Water

Once the boat is secured onto the trailer she is slowly pulled out of the water.  

Kevin and Shane blocked us on the trailer for the night right at the top of the slipway and smack dab in the middle of the yard.  Hello Norsand, Sugar Shack has arrived!

The Projects Begin Before We Are Even Blocked

The following projects are started early the next morning, before we are moved to our parking spot.

  • Removed both rudders (the original starboard rudder and the temproary rudder)
  • Removed both props
  • Removed both saildrives (this is done by Whangarei Marine as they will service them)
  • Evaluated our vinyl/stickers with Vital Signs and he shows us how to remove them

We are moved and blocked later that afternoon.  Not sure how he is able to squeeze us in between these other two boats, but he does with no problems.

Thank Goodness We Are Not This Wide

There was a trimaran that had been in the yard for 25 months!  She had a lot of work done and was finally going back in the water.  The problem was she is too wide to go down the slipway so they have to brining  a 90-ton crane to lift her up and over into the water.  

It was remarkably fast and effecient.  The yard did a tremendous job and truly was due to the expertise of the slipway team with Kevin at the lead.  The crane arrived around 8:30am and was done by 11:30am!

Boat Yard Projects:

We have scheduled a lot of boat projects with the yard, including:

  1. Haul out / Splash
  2. Waterblast
  3. Copper coat bottom (sanding down bottom paint, applying primer & copper coat)
  4. Re-Seal the deck and hull joint around the entire boat
    • In the end, we also resealed the starboard large hatch, both helm seats & stations, both davits, the bimini.
    • We also resealed / caulked the new ceiling panels in all 3 cabins, master bath. Caulked the salon around the new counter tops & around the nav station.
  5. Gelcoat repairs
    • Below the waterline: repaired small osmosis areas, small cracks, dagger boards, and sail drive casings
    • Above the waterline: both hulls had previous repairs that no longer matched the surrounding gelcoat so we blended them better; 2 small areas at starboard bow
    • Sugar scoops: both sugar scoops around cleats, steps, and by waterline
    • Deck: Port bow filled holes from old cleat, cockpit, filled crack on hatch, both entries at sugar scoop filled holes from old barrier (water stop barriers)
    • Inside: a few of our bulk heads had small hairline cracks that we reinforced and re-glassed
  6. Wash, wax, polish
  7. Prop-speed on the props

Outside Contractor Projects: Outside of the boatyard staff:

  1. Canvas: Kim is coming back to give us phifertex side panels for the cockpit enclosure and new phifertex and sauleda window covers for the salon.
  2. Whangarei Marine removed our props and saildrives.  We are replacing the bellows, clamp rings, o-rings, and seals on both saildrives.  Huge . They also sleeved, turned, polished the wear marks on the saildrive shafts and lapped the starboard cone.  An big and expensive job.
  3. Vital Signs is replacing all of our vinyl graphics, stickers, logos on the boat.  
  4. Aakron Express is repairing our EVA/non-skid which came up on the interior floor of our dinghy
  5. RH PRecision is making our new rudder shafts, then we will take them to Alert Anodising to anodise them.
  6. New custom fit rudders are being built.
  7. Denray Marine will service our liferaft and 4 of our PFDs
  8. Nautilus Braids will provide us with new main sheets, spin halyard, reefing line, Oh $hit line (hand hold off bimini), and a roll of dynema
  9. Cleigh Ltd, Matthew Duckett will install a new 220v inverter/charger.

Matt and Christine’s Projects

  1. Remove all vinyl stickers, logos and adhesive (5+ days)
  2. Replace anchor chain markers indicating length (every 10m) and clean 100m of stainless chain (3-5 days_
  3. Install heater port heater
  4. Install 12v Inverter/charger, Matt assisted with wires, breaker, installation
  5. Varnish hand rails along cabin top, flag pole, hand holds in cockpit, helm seats, princess seats, flag pole, bimini rails (all 4 sides), princess seats, and wench handle holder
  6. Clean and polish all interior wood
  7. Polish all stainless
  8. Replace window screens
  9. Repair utensil drawer 
  10. Repair wood along aft bimini (wood glue)
  11. Repair, paint, seal starboard head ceiling (5 panels have chipped paint on fiberglass)
  12. Repair 3 steps on both both sugar scoops (teak work)
  13. Sewing projects (probably won’t get to): new fender covers, new cockpit table cover, new cockpit pockets, new recycle bags, new man over board cover, new outboard cover

As you can see we are doing a LOT of work.  And it is putting my project management skills to the test!  We are hoping to get all of this done within 5 weeks!

Stay tuned for upcoming blog posts on building new rudders, coppercoat (bottom job), vinyl stickers, gel coat repairs, and canvas work.

The cover photo is Sugar Shack after removing her stickers and her bottom paint.  That is our NZ car that we bought last season and are tooling around this season (BMW 330i with 20k miles that we bought for $3850!)  What a deal!  We will sold it for the same price after we splashed back into the water.

Our blog posts run 10-12 weeks behind actual live events.  This blog happened the 2nd week of November 2023.  Did you catch our Christmas in Whangarei blog where I bake over 800 cookies and ring the bell until it upset the Mayor?

A Whangarei Christmas

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We headed to Town Basin Marina after we splashed.  It was no surprise to find that the Christmas cheer was in full swing!

We quickly put up a few lights and decorations.  Nothing compared to last year.  But I had to do something as I was judging the annual Christmas Boat Light extravaganza.  We did not have much time to do our full decorating, but we showed a little spirit.  if you recall, we won “Overall Best Boat” last year so I had a repuation to uphold.

The judges met for dinner at Local Talent, then headed to a cruiser’s boat called Rewa for drinks while we waited for sunset at 8:34pm!  Yes, it is summer here and the days are long!

Bribing the judges is strongly encouraged so we were gifted with lots of snacks, treats, and cocktails along the way.

Santa is played by Dave on the Rewa, Sharon is in the beautiful red dress next to santa.  The mayor of Whangarei is dressed in his royalty best and Matt was awarded Grinch of the year.

Santa asked that I be the bell ringer.  This was a really heavy and very loud bell.  After an hour everyone was tired of it but Santa insisted I keep ringing it – so ring I did.  That is until the mayor decided it was enough (around 10:30pm) and stuffed it with a shirt to quiet it down.

Lots of boats got into the holiday spirit with music, dancing, lights, and decorations.  It was a really great night!

A week before Christmas I finally got our decorations out.  It was killing me not being in the holiday spirit.  I feel so much better with them out.

Christmas Cookie Galor

I carried on the tradition of baking cookies for friends.  I used to do this with the ladies in our family when I was young and ever since I had my own kitchen I’ve carried out the tradition.  This year I went a little overboard with over 800 cookies (gingerbread, white mice, sugar cookies, peppermint bark), 3 batches of Toffee and 2 batches of caramel fudge!

I put together 12 gift boxes for cruising and local friends!

Myt friend Kara came over to help decorate the large sugar cookies which will be presented on Christmas day.  It was so much fun having her help to decorate – she brought her “A” game!

Of course we had the cookie monster there to help too.

There was some rose wine helping spur our creative side.

And the final product of 60 sugar cookies decorated in a rainbow of colors and designs.

A New Zealand Summer Sunrice from our dock at Town Basin Marina.

Our blog posts run 10-12 weeks behind actual live events normally.  But I moved this blog post ahead of the rest so that it coincided with the actual holiday season.

Passage: Dodging a Cyclone

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Trying to find a weather window from FIji to New Zealand requires a lot of patience and faith.  This passage is known to be one of the most challenging and difficult passages in the Pacific.  Why do you ask?  It is because you have to cross 20 degrees of latitude forcing you to go through several weather systems.  

It takes a lot of strength to prepare myself for a passage – mostly because I know I get so sea sick and it just is not fun for me.   Picking the right window is imperative to having a safe journey.  So we rely on a lot of sources and professional help.

Matt constantly checks 5 weather sources including Predict Wind which has 4 models and Windy.  Our friend Donald is checking on Maxsea and we are working with a professional weather router and hired a passage guardian.  This is on top of the assistance that we get from being a part of the Island Cruising Pacfiic Rally.  

So, we are comparing a lot of resources and information to determine when we should depart on this passage.

Time to go, NOW

We started noticing a rather ugly system forming to the NW of us.  It looked like a cyclone formation but it was way too early in the season so we were flumaxed!  After watching this formation for a few days our weather router advised us to leave immediately as this system was forecasted to go over Vanuatu and then head straight to Fiji.  Hmmmm

The problem was that another, smaller system was forming to the west of New Zealand which would make for a difficult arrival.  So, we watched for another day, talked to all of our experts and made the decision to depart.

The Plan

Depart Fiji as soon as possible and push the boat hard to ensure an arrival by the 26th of October. It is doable, but not ideal.  So, we cleared out of Fiji on the 19th of October at 1330 with a few other boats.

If you remember, our passage last season from Fiji to New Zealand (click here to re-read it) took us 6.5 days and we had a fairly decent journey.  We left with 50 other boats and were very comfortable in the weather window we selected.

So, leaving with only a few other boats in between two systems was extremely nerve racking!  The plan is to “hammer down” and just get there.  The weather models were showing a slight detour to the east before continuing on the rhum line (direct shot from point A to B).

First 48 Hours

The first 48 hours were miserable. We were bashing into the waves making it pretty uncomfortable.  We reefed the sails and pushed onward into the 3m seas.  Yuck.

We headed more east than we wanted because the winds were taking us there.  We ended up going 90nm out of our way to keep the wind in our sails.  Great, love adding more time to an already long passage.

A sunny spot during our gloomy days.  Two birds landed on Sugar Shack and enjoyed a bit of a rest.  It is really unusual to have birds land on the boat when you are hundreds of miles away from land, but it has happened.  I think this is maybe the 3rd time it has happened to us in all of our travels over the last 13 years!  

This little bird landed first and just sat at the helm.  I think he wanted to take the helm from Matt.

The second bird came a few days later when the weather eased up a bit.  It was a red foot boobie and he/she stayed with us for well over 16 hours.

On the one hand it is cool to have proof of life but on the other they poop everywhere!  We tried to shoo him away, but darn if he didn’t keep coming back.  So, we just left him there and hoped the big seas would wash his poop away.

Burning a Lot of Diesel

After two crappy days, we covered 330nm. Not a horrible start, but nothing to brag about that is for sure.  Then we were blessed with a couple of nice sailing days.  The sun was out, the seas were more consistent and came at longer intervals (still 2.5m) and we were pointing closer to the rhum line.  The down side was that we had wind on the nose which meant we had the motors on.  We fully anticipated motoring a lot on this trip as we needed to arrive before the system.  We motor sailed a lot trying to get the most out of each power source.

Matt doing a jig because the skies are blue (he is wearing his dry suit!).

During one of our particularly nice sailing periods we had a breakage.  One of our rail cars for our jib sheet decided it was done and popped off.  It made a horrible noise which forced us to jump up rather quickly.  Luckily the sheet was on the wench and Matt was able to secure a “fix” using dynema.  Not a permanent solution, but it will work until we can get a new part.

The top left is the working rail car on port side and the rest of the photos are the damaged and temproarily fixed starboard car.

A Few Good Sailing Days

We had several good sailing hours which helped lift our spirits.

And a few really beautiful sunsets and sunrises while at sea.

In the mean time we are constantly watching the two systems.  The larger system on the NW got a name…cyclone Lola.  Her trajectory is over Vanuatu and then moving over Fiji.  The lower storm (not called a cyclone yet) is still being called a Tropical Storm.  But as you can see, lots of boats have decided to leave Fiji, Minerva Reef and Vanuatu to get to safer territories.   Keep in mind that the boats are miles apart – we cannot see any of them.

Cyclone Lola

Cyclone Lola is a little brat. Even though the main system is pretty far away from us it was causing some really weird wind shifts.  All we could do was hammer down and push the boat as fast as we could.

The top images shows how the cyclone forms, the wind strength and the direction.  The bottom two photos show how truly dangerous this cyclone is.

Cyclone Lola decided to head more SE and looks like it will converge with the Tropical Depression that was forecasted to hit NZ.  Wonderful!  I am sure you know, but red is bad, black is worse and gray is horrible.

Lucky for us we were able to skirt the outer edges of the storm and make it in to port without too much trouble.  We arrived in NZ on Thursday morning and were rafted up to our friends on Dandelion by 0900.  Thank God!

Formalities

We patiently waited for the officials to come onboard including bio security who took a ton of food, customs and immigration.  They even brought a dog onboard (that was a first for us) to sniff for weapons, drugs, and cash.  Look at his little booties…so darn cute.

New Zealand has very strict biosecurity rules.  We are not allowed to bring in shells, wood carvings, feathers and lots of foods.  Prohibited foods include all meats (cooked, uncooked, canned), dairy, cheese, nuts, produce, vegetables, fruits and more.  We had provisioned for three people to be at sea for 10 days.  Since it was only 2 people at sea fo 6.5 days we had a lot left over.  It is hearbreaking to watch them throw away perfectly good food.

But….we are super happy to be back in NZ and safely tucked in a berth.  

Pasage Summary

  • Total Miles, on rhum line: 1097
  • Total Miles Traveled:  1179
  • Total Time:  161.36 hours / 6.5 days
  • Total Engine Time:  72hours (YIKES)
  • Average Speed:  7.3kt
  • Max Speed: 12.1kt

Just some of our Tasty Passage Meals:

Matt prepared loads of tasty meals.  I was a little distracted and only got photos of a few dinners.  Below we have seasoned pork chops with grilled onions, grilled pineapple and mashed potatos.  To the right we have seasoned chicken fajitas with bell peppers and onions.  Bottom left is Matt’s famous bahn Mi and pulled pork over a baked potato.  Yummmm.

Our poor Island Cruising Pacific Rally 2023 Flag took a beating during our trip from New Zealand to Minerva to Tonga on to Fiji and back to New Zealand.  She deserves a rest.

All in all it was not a horrible passage and it certainly could have been a lot worse had we gotten caught in either of the storms. I am so grateful that we have such a strong and well made boat and a captain who takes care of both of us.  It would not have been such a favorable passage without the help of Donald, our weather router, the passage guardian, and Viki with Island Cruising.

My favorite shots…look at the sliver of a moon in the top photo.

Our blogs run 8-10 weeks behind live events.  This blog occured toward the end of October.  Did you catch our loast blog where we do all the prep work for this passage?