Winter 2003 Project List

The first step in any project is to categorize and prioritize the list, normally I select an A, B, and C list. Normally before departing on a trip all of the A and B list items are finished. This time I am working up to deck painting so anything which impacts the deck painting ends up in the high priority list. Since the decks will most likely be painted in the slip but the hull will be painted during haul out this results in a second list.

Things to do before deck painting:

[ 100% Complete] Remove all deck hardware (Almost everything is off the decks, still have to remove forward hatch, dorade boxes, steering system, and some other small things), Forward hatch removed, port dorade box removed, steering system removed, leaving a dorade box, companionway hatch jams and some other small pieces.
[ 100% Complete] Install new Rub Rail (Tom found a wonderful source of material which is now installed but needs to now be removed for painting, still need to find clean solution to cover aft ends of rub rail, the remaining 5%)
[ 100% Complete] Remove New Rub Rail and Store
[ 100% Complete] Remove Solon Portlights (Outer frames removed from coach roof [12/21/03], Digging out the Lexcell sealant around the existing Lexan, all should be out soon, Lexan Removed and sent to shop 1/7/2004)
[100% Complete] Fabricate new Solon Portlight Lenses (Located sheet of 1/2 inch thick Lexan MR10 and the shop can cut out the pieces using the existing portlights as a template, anticipated return of portlight lenses 1/9/2004 but Lexan Sheet was damaged upon arrival at "Plastics Depot" they have ordered a new sheet. Completion of cutting expected 1/13/2004, Completed 1/16/2004)
[ 100% Complete] New gate stanchion Old gate stanchion is at Riley Stainless, they are fabricating a new one 4/20/04 (Found damaged gate stanchion, will take to Riley Stainless next week to make a new one)
[ 100% Complete] Rebuild stern pulpit Riley looked at stern pulpit and recommended complete replacement as a better solution, just too many places where it has been tweaked. Having cockpit seats added to new design. (Stern Pulpit is off the boat and ready to take to Riley)
Forward and Aft Lowers are mounted on vertical bulkheads and don't have a fare run to the stay, is it possible to wedge or shim the bulkhead to match the angle of the shroud?
Permanent attachment point for running backstays? (Perhaps new chainplates half way back from the existing aft lowers to make a good place to attach the running backstays?)
[100% Complete] Roller Furler on Inner Forestay? (Decided against it based on the foredeck being the only reasonable place to inflate a large dingy)
[ 95% Complete] Replace below decks steering gear to remove run across to hull (Looks like will have to replace entire steering system except the quadrant on the rudder post to solve this problem, the additional storage space alone makes up for a significant amount of trouble, All below decks equipment removed 12/30/2004, working on replacement system). Replacement Edson system has arrived (4/10/04) starting to modify mounting locations for the larger sheaves. 10/1/04 Final testing of installation, sheave installation on heavy plywood frame to verify performance and installation. Winter 2004-2005 will see a new steel frame installed to complete the installation.
[ 50% Complete] Move cockpit mounted bilge pump to make dingy storage easier Pump removed, hole glassed up, need to reinstall in new location
[ 100% Complete] Repair decks where old deck penetrations need permanent fixes (glass over existing holes which need patched)
Cockpit actuated autopilot clutch lockout (This is simply a switch in the autopilot clutch circuit to allow immediate and permanent disengagement of the below decks autopilot for emergency maneuvers or when the vane is steering the boat)
Wash down pump outlet on foredeck
Fresh water shower in cockpit
[ 100% Complete] Install new hatch in Head 10"x10" hole cut in deck 1/10/2004, built ring to make deck locally flat 1/11/2004, need to complete and fair the ring and attach to deck, 1/18/2004 finished ring and epoxied down to deck, need to complete final filleting and sanding. All paint work complete, just need to bolt down the hatch after the last of the painting is complete.
[ 35% Complete] Install remote mike in cockpit (Have remote mike and it works, need to select installation location), decided to install remote mike in the new Edson binnacle.
[ 100% Complete] Better installation of propane control solenoid (Install in small locker, just a small locker for the propane regulator and solenoid ) , obtained a pelican dry box and built up solenoid control, glassed up existing holes in cockpit, once new binnacle is installed can make final installation. Long term considering building a locker inside the transom for the propane bottles.
[100% Complete] Verify operation of RLB23 beacon, battery now 13 years old, specified life is 10, replace battery or remove unit? (Cost of new battery is very high $600, so removed self launching storage from deck and sealed holes), Verified that the unit no longer functions, removed completely will dissect unit for interest.
[ 100% Complete] Refurbish Lighthouse Windlass (Preventative Maintenance since off boat) (Sent to Lighthouse 01/21/2004), Windlass came back looking like new. Replaced leaking seals, re-greased gear box, some new bearings (showed light wear but are inexpensive while in the unit), drive motor has new sealing technology and protective cover
[ 80% Complete] Chain Counter and Reverse Switch for Windlass? (Chain Counter is about $500, Reversing switch assembly $500, may go for it to make it easier for me to keep track of how much chain is out and be able to complete lowering the chain from the cockpit), purchased both, the reversing solenoid box is installed in the chain locker. Remote/chain counter will be installed on the binnacle.
Upgrade diesel engine intake filter and air source (Portion which impacts the stern deck needs to be taken into account before painting)
[ 100% Complete] Upgrade Genoa Cars with Harken Ball Bearing System? (Currently planning to use Harken Big Boat cars to match the traveler, remaining question is how far forward to carry the track and then order the components) (Naw, decided the current system will be fine for the time being.
[ 100% Complete] Monitor Vane Control lines through cockpit floor? (Naw, like it accessible)
[ 90% Complete] Move Sailing instruments and glass up holes, move above companionway on seahood (Instruments removed, holes glassed up, need to modify seahood to handle instruments. Question, will it be better to just buy a remote monitor for the wind point so all I have to run to the seahood is seatalk buss?), instruments removed, holes are glassed up, some instruments will move to binnacle, some to an additional pod ABOVE the sea hood which will require no sea hood modifications.
[ 100% Complete] Sand decks smooth (remove old non-skid and then use grit to provide traction in new paint)
[ 99% Complete] Paint Decks with LP (Decks all have build coats of LP, final coats will be applied after returning from the boat yard to prevent scratches and damage in the yard from being an issue. There are three remaining areas to put two coats of non-skid on. Sea Hood, companionway hatch, and cockpit locker.

Things to do before Hauling for Hull Painting

Replace transom exhaust fitting (add shut off valve?)
New stern light
[ 100% Complete] Remove Monitor Self Steering Vane
[ 100% Complete] Remove Hull Numbers and Stickers
[ 100% Complete] Determine Correct Cutless Bearing (it is one of two possibilities, perhaps just order both and return one?), ordered both, turned out to be the 2" diameter bearing (Dogfish)
[ 100% Complete] Obtain PSS Replacement Bellows
[ 100% Complete] Determine best approach to seal kelp guard mounting holes Obtained 4 silicon bronze bolts, 5/8" diameter, 3 inches long with a shoulder which is about 1/8" less than the hull thickness in the keel. Large (a little less than 2" diameter) bronze washers on the inside and outside of the hull with a bronze nut on the back. The entire setup beaded heavily in 3M 5200.
Install rollers on dock and new rub guards to protect paint
Purchase Copper communications ground plate

Things to do while hauled for Hull Painting

[ 100% Complete] Grease Rudder Post
[ 100% Complete] Replace Cutless Bearing
Install copper communications plate
[ 100% Complete] Permanently seal kelp guard mounting holes
[ 100% Complete] Minor Blister Repair
[ 100% Complete] Replace PSS bellows
[ 100% Complete] Rebuild MaxProp
[ 100% Complete] Paint Hull with LP, Currently (5/9/04) there are three coats of LP on the hull, there was a minor missed spot which I had to touch up, will determine this week if it is good enough or if the hull needs one more coat.
[ 100% Complete] Bottom Paint, 6 Coats of Micron Extra with Biolux are being applied. The color scheme is 1 coat of red, 1 coat of green, 2 coats of black, 2 coats of blue. Should be ready to reblock the hull on Thursday 5/13/04 and apply all 6 coats of Micron Extra to the cradle stands and keel.