Tag Archives: phil waddell

Comfort Upgrades

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There were a few more upgrades that we wanted to do this year including adding “rain flashing” over our 4 large window hatches and adding a back rest in our cockpit.

These might seem like “small” upgrades but they add a lot of comfort value to the boat.

Quick Upgrade Summary:

  • Rain Flashing for windows
  • Back Rest in Cockpit
  • Inflatable Fenders
  • Forward Scan Transducer
  • VHF Microphone at the Helm

Rain Flashing

Sugar Shack has (4) large hatches and (3) small hatches on each side of the boat. The large hatches let in a lovely breeze and are open as often as possible.

However, when it rains, we have to run around closing all of the hatches to prevent water from getting inside the boat.  

As you can imagine, it gets very hot in the tropics.  When it rains and the large hatches are closed it becomes unbearable on the boat. 

The water drips into the cut out which then drops behind the hinge and into the boat.

We had to do something that would allow us to leave the windows open during the rain without soaking the interior.

Ian on Tavake (a Catana 431) had made rain flashing that inspired us to do something similar.  Unfortunately he no longer had the mold so we had to start from scratch.

Scott our fiberglass fabricator was able to make a pattern to build the mold.  

We were able to make 4 rain flashings for our large windows once the mold was completed.

Matt scratched the back of the carbon pieces, adhered 3M VHB tape and we were done!

Shortly after install we had our first rain and they worked perfectly.

Back Rest in Cockpit

A small yet irritating issue with the cockpit is the lack of back support. 

Many Catana owners added a back rest that sits between the salon main window and the cockpit main seating.

Our friend Eric, on El Gato (Catana 472) had drawn up these design specs.  We used this as a guideline and made our own modifications. 

However, we did not want it as tall so we made it shorter than the 10 3/8″ height. 

In addition, we wanted a round, not square mounting bracket.

Once the back rest was manufactured we had it electro-polished at Spiralweld in Auckland.  This will protect it and keep it shiny with minimal polishing effort on my part.

New Inflatable Fenders

Sugar Shack came with (4) A4 large, round fenders and (8) F4 pencil fenders.  We later added fender covers to protect the fenders and the boat.  These fenders have served us very well.  However, they do take up a lot of space in the forward bow peak.

So, we decided to purchase new inflatable fenders.  We went to Hauraki Fenders and purchased (8) Medium 350x1100mm (1’x3.6′) fenders and fender covers.

We are super excited to try out our new fenders!  For safety reasons, we kept the (4) A4 round fenders so that we always had fenders at the ready.

I did not want to unpack the tightly packed fenders for a photo op so you get a generic photo. 

Forward Scan Transducer

We decided it was time to purchase a forward scan transducer which will allow us to see the gradient ground levels in front of us.  

This forward-looking sonar provides a clear two-dimensional image of the bottom in front of us, allowing us to navigate shallow or poorly-charted waters with confidence. With real-time updates and a forward-looking view of up to eight times our current depth.

This will be a useful tool while anchoring.  We bought it from B&G for roughly $1200.

VHF Handheld at the Helm

We have our “big” VHF at the navigation station and (2) small hand held VHF units.  However, we have never had a VHF Microphone at the helm station.

A rather small inconvenience, but one that has irked us for awhile.  So, it was time to install one.  Matt ordered a white ICOM IC-HM 195S Command Mic IV from Amazon for $241.

Purchasing and Contact Info:

  • Scott Banks, Fabricator, Whangarei, NZ +64.22.380.3972.  Fabricated the helm pedestal extensions and the window rain flashing
  • Stainless Fabricator: Phil Waddell, hardout98@icloud.com, and his wife Joy Waddell, joyw2@icloud.com. +64.21.280.6356
  • Spiraweld, www.spiraweld.co.nz, +64.09.576.1199 

Be sure to check out our other upgrades on “Impactful Upgrades” blog post.

Our blog posts run 8-10 weeks behind actual live events. 

We worked on these two projects for several months over November 2025 through January 2026.

Solar Arch Installation

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After months of planning, two test fits, and countless discussions, we were ready to install our new solar arch.

Be sure to read Part I “Solar Arch Design & Fitting” before you read this blog post.

After our fitting, Phil, our stainless fabricator, took our partially made arch back to his workshop.  He had another 2 weeks of work to do including:

  • installing the “ladders” on both sides of the arch
  • connecting the truss to the arch
  • adding support tubes
  • making all of the access points for our lights, antennae’s, and equipment
  • create the mounting brackets

Once he was done with his work, Phil will sanded and polished the entire piece.

Shine Like a Diamond

The next step was electro polishing at Spiraweld in Auckland.  This was tricky as the arch is so large it makes driving long distances at fast speeds difficult.

What is electropolishing?

It is an electrochemical process that removes small peaks and burrs from the surface of the metal part generally improving its smoothness and giving it a shiny appearance. The process is a form of electrolysis, the acid electrolyte acting as a conduit which removes metal ions from the surface of the stainless steel part.

Electropolishing will enhance corrosion resistance and will make it look bright, shiny and ultraclean.  It will also prevent corrosion which will reduce our cleaning.

The Damage

Spiraweld had asked us to cut the arch in half to prevent damage to it.  We knew this might be a possibility but we had really hoped they could dip it as one piece. 

Phil, our fabricator was there and cut it in half to make it easier to dip in the bins.  So imagine our surprise when we got a call that the arch was dropped and damaged!

Evidently, the leg of the arch hit the side of the bin in multiple places. For F@CK sake!  We had been so careful for the past few months in transport.

I know it does not look like much the tube is 75 mil in diameter and 1.6mm thick.  It is big, but light.  Dents like this will compromise the strength of the leg and cannot just be bumped out and polished.

Phil ended up cutting it off and sleeved it to make it stronger than the original.  Seriously more time, more money. Unfortunately, we will always be able to see the “wave” in the stainless.  It is impossible to get it out completely without completely redoing the entire leg.

To add insult to injury, we had another problem.  Phil accidentally shattered the bottom part of one panel when he was attaching it to its plate.  This has not been a good few days for us.

INSTALLATION DAY

The BIG day has arrived!  We were super anxious for today after 4 missed installation dates and all of the damage.  Phil arrived at 5:15am and we got to work.  We had to drill holes on two of the four remaining panels.  Great way to amp up the stress levels as you put a drill close to your brand new glass solar panels!

Next we began running mouse lines to help get some of the wires through.  It is super tricky to run the lines as there are 90 degree turns and false holes to avoid.

Culham Engineering sent the crane promptly at 0800.  By 8:20am we had our baby flying above the masts. 

We have two people on each side with lines controlling the movement as the crane lifts it above our mast and behind our boat.

We use a ratchet line to pull the arch together (side to side).  We test fit it first, mark the boat, pull the arch back and start drilling holes.

It is horrible to watch someone drill holes into your boat – but what can you do?

Conclusion

Nobody got hurt, the boat was not damaged and the arch is somewhat installed.  Good.

It took 3.5 hours with the crane and an additional 2 hours with Phil.  We had the bolts in but were waiting for proper backing plates to permanently secure the bolts.

Issue:  We thought the front legs would bolt into the engine compartments (behind the bulk head).  But to our surprise the bolts split the bulk head.  So, one bolt was inside the engine room and the other bolt was on the other side of the bulk head.  The only way to reach that bolt is to remove the ceiling panels from the master cabin and office.  

Yet, another project.  

It took us 4 additional days to fabricate new backing plates, get new (shorter) bolts for the ones in front of the bulk head, make 2 new vertical legs (for additional support), and use sika flex to secure everything together.

We still have the ratchet lines and our topping lift attached to the arch to secure it.  These remained in place until everything we properly assembled.

It took us an additional 2 weeks to complete the arch.  We had hire a scissor lift to finish running all of the wires and install of the additional equipment.

The solar arch installed while at anchor.

Matt designed it so well.  He followed the same lines of the bimini legs and the same curve of the bimini to make them two mimic eachother.

Contacts

Stainless Fabricator: Phil Waddell hardout98@icloud.com and his wife Joy Waddell joyw2@icloud.com. 

Phil is NOT interested in building another solar arch like ours (it was too big).  However, he is open to smaller arches and other stainless fabrication.

Our blog posts run 8-10 weeks behind actual live events. 

Check out our last blog post on the solar arch design and fitting.

We started working with Phil in early November and had the fitting on 16 December 2025.

Solar Arch Design & Fitting

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The dream of adding new solar panels just got so much bigger than anticipated.  

Instead of just buying and installing new panels we decide to build a new solar arch spanning the width of the boat (over 7 meters wide and 3 meters tall).

We circle back to our friend Dan on Sel Citron (Catana 52) as he had his solar arch built at Norsand in Whangarei, NZ.  He hired a stainless fabricator named Phil Waddell.  So, we contacted Phil, explained what we were looking for and hired him.

Matt created a design plan of what we were looking for which was similar to Sel Citron but a smidge wider.  

I wrote up a full 10 page document identifying our design process, specifications, must haves and like to haves.  Comment below if you are interested in seeing this.

We want our solar panels to be inset and not sticking out or above the solar arch.  In order to get this look we plan to have the arch go from the outside of each hull.  Sel Citron went on the inside of each hull making his arch narrower.

The solar panels will also run perpendicular to the boat with the longest length of the panel running from port to starboard.  This will maintain our boat length of 14.5m (47′).

Measurements

Our fabricator, Phil Waddell came and took extensive measurements as he and Matt talked through the design.

Big decisions were made about the thickness of the tubes, the angle of the poles, the connecting, points, the conduit entry/exit points, weight, size, and location of each piece going on the arch, and attachment points.

Design imperatives:

  • The poles (tubes) had to match the angle of the bimini supports (same trajectory)
  • Dimensions of the arch could not extend beyond our davits as we did not want to increase the length of the boat.
  • The width of the arch would extend from the outside of each hull making it about 7 meters long.
  • The solar panels had to sit flush inside the arch supports.  We did not want the solar panels to sit on top or overhang on any of the edges.
  • We wanted the entire arch to be electropolished.
  • Each of the four corners and center points have to have entry/exit points for cables and wires.

Phil and Matt decided that the diameter of the poles would be 75mm.

The Fitting

Phil had to buy an extendable trailer hitch to transport our arch from Kerikeri to Whangarei (1hr20min). 

There was a lot of noodling over how to test fit the arch. 

We decided a forklift might work but we quickly realized the yard’s forklift could not lift the arch high enough.

So, we hired Culham Engineering to bring a crane.

It took five of us to gently fly this arch into place.

Matt and Phil attached lines to help guide the arch as she was raised above the boat masts.

We raised the arch above our neighbors mast, and over our mast before slowly lowering it behind our boat.

Phil used “handcuffs” between the forward and aft legs for support (they will not be there permanently. However, because the handcuffs were temporary it negatively impacted the fit.

Phil had to do some adjustments and mark the bottom of the legs for placement.

It took us about 2 hours to do the fitting and at least 8 hours of preparation.

Stay tuned for the installation of the solar arch in our next blog post.

Contacts

Stainless Fabricator: Phil Waddell hardout98@icloud.com and his wife Joy Waddell joyw2@icloud.com. 

Phil is NOT interested in building another solar arch like ours (it was too big).  However, he is open to smaller arches and other stainless fabrication.

Our blog posts run 8-10 weeks behind actual live events. 

We started working with Phil in early November and had the fitting on 16 December 2025.

Our blog posts run 6-8 weeks behind actual live events.  We worked on the solar arch from Nov.2025-February 2026.

Don’t miss our massive project updating our fresh water tanks in our last blog post.