Failure to Launch

Another day, another delay. As we worked in the yard, day after day, week after week, month after month, we dreamed of the day we’d finally splash back into the water. We almost splashed March 9 but the lift was booked up so we delayed 1 week. We almost splashed March 16 but the lift broke so we delayed 5 days. We almost splashed March 20 but our new rudder bearings were 1 mm too small meaning we could not put the rudder back in so we delayed 1 more week. Then a cyclone came bearing down on New Zealand, putting into question our latest reschedule for splashing. We have been working so hard, and feel like we are further behind than when we started. That’s not true, but the delays have been demoralizing at times.

What the $!&# happened with the new rudder bearings?! (I’m sure you’re asking yourself.) Well, long story short, we ordered bearings through Outbound Yachts with a 99mm inner dimension based on the factory specifications for our boat, but it turns out our rudder post has a circumference of 100mm. That 1mm mistake cost us at least one extra week on the hard as we sorted out a solution to this problem. Talking with the bearing manufacturer we learned that the specific bearings we ordered had a maximum size of 99mm so there was no way we could order the same thing with 100mm inner dimension. They offered to make us a different style and said they would be ready in about 5 weeks, and then could be shipped from The Netherlands to New Zealand. We declined this option and instead found a local shop just down the road from the yard. They made us solid state bearings out of our preferred material (Vesconite Superlube) and it only took 3 days! With new bearings in hand, we scheduled our lift to install the rudder and splash for March 27.

It was blowing hard and dumping rain for the days leading up to our new splash date due to the cyclone. It rained so much that our high bilge pump alarm went off! In heavy rains, water makes it way to the bilge via the mast. Our mast is keel stepped meaning it passes through a hole in the deck and goes through the interior of the boat down to the keel. Since we’re on the hard we have shut down many of our systems, including the bilge pumps. Our high bilge pump alarm is battery operated so still running even with the pumps shut off. It was a good test of alarm function! Luckily we were home and simply turned on the bilge pumps to empty out our rainwater collection.

With all this spare time on our hands in the yard due to our delays, we continued with the to do list. After the failed attempt to put the rudder back in on March 20 (which required the lift and a fork lift) we had them settle us back down with the support stands in different spots. This allowed us to paint Copper Coat onto the final remaining unpainted stand spots and bottom of the keel. Additionally we lubricated and exercised all the through hulls and injected grease into our Max Prop propellor. We typically inject the propellor grease while diving as it needs to be done more frequently than we haul out. I must say it was quite a bit easier to hold on to the tiny zerk fittings standing in the yard than it is underwater.

We received our rebuilt hatches. The new acrylic is so shiny and clear! Unfortunately, the supplier for Lewmar hatches for all of NZ was completely out of new hinges and handles and expected a new shipment in a few months. So we could not replace all the parts we intended to replace. At least we have what really matters – new acrylic and new gaskets. We checked a US shop and it had the parts in stock. We quickly purchased them and shipped them friends who are coming to visit next month! The hinges/friction levers for the large hatches actually cleaned up nicely, so we didn’t need to buy new for those, only a couple for spares. In all the rain we’ve been able to test our the new gaskets on the hatches. We’re happy to report they are working great. We no longer have little puddles on the floor or drips on the ceiling. Drips and puddles weren’t too bad before the replacement but they were only going to get worse.

We inspected the diesel tanks and happily found no problems. We’re looking primarily for any water that has made its way in to the tanks and for any diesel bug or debris. Diesel bug is made up of microorganisms that grow in diesel, particularly if there is water intrusion. Diesel bug forms a dark colored gunk that can damage the engine when it gets pulled out of the tank into the diesel loop. We have thus far avoided the dreaded diesel bug by only buying fuel from legitimate fuel docks and by treating the diesel each time we fill up with a purpose-made biocide. So far, so good.

We started the project of installing ventilation to the engine compartment and it is nearly finished. This involved cutting two holes in the stern of the hull and installing vent covers. It’s always a little nerve wracking to cut holes in the hull. Then a hole was cut in the engine compartment wall and another one in a bulk head between the engine compartment and the stern. This allowed us to install rubber/plastic ducting running from the engine compartment to the stern. Ultimately, a fan will be installed in the engine compartment that will suck out hot air for discharge via the ducting and the hole in the stern. The second hole in the stern is for fresh air ingress to the aft lazarette area which will make its way into the engine compartment via the centerline bilge.

We tackled steam cleaning all of our cushions below deck and in the cockpit. It was a classic boat project that sounds simple when you write it on the list, but comes with multiple hidden challenges. First challenge was renting the machine, since they required a NZ mobile number to confirm identity. Thankfully our local friend Ava jumped in to help us rent it! The next challenge, and the reason we decided to do this project in the yard, is that the machines run on 50 hertz and our electrical system is 60 hertz. We knew the yard had extension cords available so we borrowed one of those and plugged it in to the 50 hertz shore power. The final challenge was that the machine required an input of warm water. Being on the hard, we have our hot water heater system shut down so we only have cold water pulled from the tanks coming out of the tap. So we boiled water using the electric kettle and mixed it with cold water to get the necessary warm water for the machine. All things considered, the steam cleaning went well and our cushions are looking quite nice. It was rainy and wet all week, and our local friends lent us a dehumidifier to help us dry the cushions. By the next morning they were dry and we sprayed them with a non-toxic fabric protector we imported from Australia. A full day with the dehumidifier humming away and the cushions were dry again and ready to be put back in place.

We took a mental health day with cruising friends and visited the Ngawha Hot Springs. It is a simple set up with 8 pools of varying temperatures, with concrete walkways, wooden walls and seats in the springs, and sandy bottoms. Then we were off to Kerikeri to explore historic European and Maori settlements along the river. We found a delicious dinner spot in Kerikeri surrounded by a beautiful botanical garden and enjoyed a stroll through the garden while sipping feijoa cocktails. Taking these breaks from the yard are refreshing and necessary to keep us going through the delays and frustrations.

On March 27, the storm cleared and the sun poked through a thick veil of fog. Burnishing of the hull got underway by 8am. As we’ve mentioned in other posts, the final step for Copper Coat is to burnish (aka sand) the hull to expose the copper in the paint. The copper is what prevents marine growth. Next up the person we hired to install the bearings and help get the rudder back in came by and got to work. He’d already done some fitting of the bearings the day prior. We had also checked and double checked the inner dimension and were able to slide the bearings on & off our rudder that has been laying on a palette under the hull for the past week. Then came the time to lift the boat and bring over the forklift to help raise the rudder up into place. We were both on pins and needles all day, not wanting to get our hopes up, but still hoping with every ounce of our beings that we would get the rudder back in. Good news, we got the rudder back in and splashed on Friday evening as scheduled! Bad news, the bearings are far too tight and it is difficult to move the rudder with the steering wheel. We hoped that maybe settling down in the water would help because the hull shape can shift a little between hanging in the slings and floating in the water. Additionally, water can help lubricate the rudder bearings, though ultimately the material we chose is designed to not need any lubrication. However, after sitting in the water overnight, we came to the crushing realization Saturday morning that we would need to haul out again and fix the bearings. A quick chat with the machinist who made the bearings confirmed they will need more machining for a proper fit.

Next Stop: Back in the yard to correct the rudder bearing size and alignment