Calling all boat project fanatics, this one’s for you! Boy, did we have a time trying to get our engine aligned. While Phillip and I knew we had some kind of issue going on with our prop shaft, the key that fits in the shaft (which was always coming out and we were hammering back in, brilliant plan!), and our coupling, we didn’t know it was quite as bad as it was.
Watch along as Brandon, Shane, and the great team at http://www.perdidosailor.com help us diagnose and solve many issues relating to our prop shaft and how it seats in the transmission. We had a machinist re-engineer our old coupling and make us a new one. We also re-bedded the strut and replaced the gutless bearing.
And, just as boat projects always do, the boat had a lot of extra hidden work in store for us in the form of a rotten engine stringer portion (under the raw water pump on starboard, no surprise) that we had to repair along the way. Fun, fun! Misery loves company! Give it a watch! More photos and write-up available at http://www.havewindwilltravel.com.
I hope you all have been enjoying these shipyard videos while Phillip and I were off galavanting across the Atlantic Ocean. We’ll have plenty to share from that adventure once we get our heads back on straight. It can be hard, at times, to transition from offshore sailors back to full-time lawyers/marketing gurus. But, the work is always worth it. In exchange for all of those photos and videos of us out sailing and traveling the globe, enjoy seeing us here all grimy and greasy wedged down in the engine room on our boat! You’re welcome! B.O.A.T., am I right? : )
Maybe they should change that B.O.A.T. saying to “bonded or about to.” The hardest part of our rudder drop was getting the stinking quadrant off! Heat, impact, cheater bars, nothing would work. So, the creative guys at Perdido Sailor had to come up with a different fix, and boy did they!
Ahoy crew! Shipyard Vid #2 coming at you, from Cascias, Portugal nonetheless! I put this video together a while back so you all would have something fun to watch while we were embarking on our second Atlantic-crossing helping deliver a new Lagoon across the pond from France to the USVIs! I know how you all LOVE boat project videos, so here’s another one for you from our interesting work at the shipyard this past summer.
While I wrote about this project several months back here, some of my followers love to see the video! This one’s for you! Phillip and I always enjoy working alongside the guys at the yard because we learn so much. They point out problems we didn’t even know we had and teach us fixes we didn’t even know were possible.
Watch here as we (finally!) get the quadrant off and make the necessary modifications to do that, check on our G-flexed keel seam from 2016, replace the cables for the throttle and shifter (because, according to Video Annie, they sounded like “Grandma’s panties coming down”), and shared some fun lighthearted joshing at the yard!
We hope you are all enjoying the shipyard videos and having a great time tracking us along while we are sailing back across the Atlantic Ocean. Follow on our facebook page at www.facebook.com/havewindwilltravel for real-time updates and locations via our Delorme!
This is it! The post you all have been waiting for. Now that the stringers under our engine are repaired, it was time to get Westie back in place and aligned so we could tackle one of the projects we were most excited about this year: PAINTING THE ENGINE!
Phillip and I have had Westerbeke-red visions dancing in our head for weeks. The thought of having a completely leak-free (or even just less-leaky-than-before) engine that would be bright, shiny red, ready to point the finger vigorously and immediately at any leak really pops our corn. Phillip and I were both super excited to get Westie assembled, all cleaned up, and ready for a few layers of sweet Westie red. And, as many of you have asked us about this process (this was probably the most commented-on post from our shipyard Facebook photos), we wanted to share with you all the process in case any of you are thinking of doing the same. To be honest, this paint job, while probably one of the most visibly-rewarding of our projects this summer, was by far one of the easiest.
First, let’s talk a little about why we wanted to re-paint the engine. While a fresh coat of paint would, as I mentioned above, greatly enhance our ability to spot and troubleshoot new leaks from the engine, I later learned this was not the primary goal. What were we really trying to accomplish in cleaning and painting our engine?
As Brandon with Perdido Sailor explained, the number one thing to really rob years of life from your engine is corrosion and decay from rust. Phillip and I were definitely seeing evidence of that in the layers of metal that could easily flake off of our engine, primarily on the backside where it is the greasiest and near the water pump where it suffers the most rust corrosion. This part on our engine, the cradle support on the back, had probably suffered the worst of the rust, so Brandon devised a good plan for us to take the rust head-on and prevent further decay.
Let’s talk a little about this product: POR 15 Industrial Rust Preventer
It’s a three-step process for cleaning metal, prepping it, then painting a rust-preventative coating on it, which chemically bonds to the metal, before the final paint. We special-ordered it from Amazon so we would receive it in time to apply to the cradle before it was time to re-assemble the engine.
That was the plan anyway. Phillip followed the instructions to a “T” using the cleaner, then the prep, then the POR paint, followed by Westie red. We also woke early and were at the shipyard before 6:00 a.m. that day to apply the POR before the humidity rose in the heat of the day. Living in humid, muggy Florida, this was one downside of the product:
POR-15 is cured and strengthened by exposure to moisture and will dry faster under extreme humidity, but moderate to dry atmospheric conditions are most desirable when applying this product, because extreme humidity may cause an immediate surface cure, trapping carbon dioxide gas below the surface. When this happens, bubbling may occur. Extreme humidity at the time of application may also interfere with proper adhesion of the POR-15 coating to metal because it’s almost impossible to keep metal dry under such conditions.
Yep, you read that right. If it’s applied in too humid of an environment, bubbling can occur. For us, bubbling certainly did occur.
Just a few scrapes with Brandon’s knife and both the red and the POR were flaking off back to pure metal.
We’ll have to call this attempt an epic fail.
But, we’re determined sailors. With reassembly of the engine scheduled for the next day, Shipyard Annie was sent in to try and remedy the damage to keep us on track. It was either spend the day stripping all of the paint off of this beast manually (including the areas of mega-bonded POR that did cure properly) or—Option B—whip out this toxic devilish serum for a chemical strip:
Have any of you ever used this product? I mean damn! It will peel the paint off your nails. That stuff was super intense. But, it was our quickest option. Phillip picked up a similar brand from the auto parts store and Annie set to it.
The minute I started slathering it onto our cradle, the paint started hissing and bubbling in violent (albeit futile) revolt!
It literally took me 12 coats of this acid with scraping in between to finally get the POR to let go. Everyone at the shipyard said it looked like a murder scene!
It was also a little painful too. Even through gloves, after multiple applications, the toxic aircraft paint remover began to make my hands feel cold at first, then they started in with a painful tingle. I was honestly worried I might be unknowingly inflicting permanent nerve damage on myself. I checked with the guys at the yard to be sure and they said it’s painful but temporary. So, my murdering continued and finally we were back to bare clean metal for another attempt at the POR.
Brandon helped supervise this time and we applied it initially in his air-conditioned, somewhat-enclosed shop area. (He has what I call “butcher freezer” plastic flaps that hang down, keeping the room cool for the guys but easy to come and go with tools, paints, whatever in your hands.)
Even with Brandon helping with the application we were still getting a little bubbling at the shipyard, so I took the pieces home to our fully-air-conditioned apartment for the final coat and the second time around resulted in a solid cure of the POR under the Westerbeke red.
That piece was easily the hardest part of this job. After the cradle was in place, and the engine reassembled (with a successful alignment check by Brandon and Shane), Phillip and I were finally given the go-ahead to paint. Say it with me: “Whoo Westie Hoo!”
Our first step was to clean the engine thoroughly with Zep. That is some awesome de-greasing stuff. Perfect for this situation. Simply spraying Zep on and rinsing alone took off the majority of our oil and grease for painting. This is the difference in the engine from merely dirty to clean.
We then scraped off any paint that was ready to jump ship. Our goal was to get as much bare metal as we could exposed so we could start fresh with primer coats there before the final red coat.
Our next step was prep. Shane with Perdido Sailor gave us a good tip to cover all of the hoses and wires and other fittings on the engine that we did not want painted with aluminum foil. It was nice because it was easy to work with and would wrap around pipes and fixtures and (for the most part) just hold itself there, which made the prep work much quicker, albeit still a good three hours. We were also careful to tape and cover caps, dipsticks, the throttle and shifter cables, the intake, etc. When we were done, we had an odd-looking foil monster in the engine room.
Then it was time to paint. A follower on Facebook captioned this photo Boat Project Magazine’s August Centerfold. I’ll take that! : )
On Brandon’s recommendation, we started with green zinc chromate on all areas that were bare metal (which were a good bit!). The fumes were pretty intense in the engine room so we donned a mask and goggles. A follower later recommended I probably should have thrown on a Tyvek suit for skin protection, which would probably have been much smarter. We’re told the chemicals in that zinc chromate are pretty harsh. If I start growing a third eyeball, I’ll let you all know. But, you can see the green areas in the photos below.
Outside near the Perdido Sailor shop, Phillip was also painting the heat exchanger before we put it back on as well.
The next step was a grey primer over the green zinc.
The fumes were pretty intense, particularly down in the engine room. But with a mask and goggles, the job wasn’t too bad.
Finally everything was ready for our favorite shade of red. And, I can’t tell you how many times this awesome scene from Kinky Boots was repeated at the yard when we were getting ready to start spraying the Westie red! I mean “Reeeeeeddddd” (with a hiss).
“Red is the color of sex! And fear. And danger. And signs that say “Do not enter.”
But, all of our signs say “Yes, indeed, do paint!” Let the Westie Red fly!
Now you see grey. Now you don’t!
Yeah baby! We were tickled red to pull the foil and tapes and drapes all finally away from the engine and admire her new coat. I dare say Westerbeke red and Bilgekote grey are my new favorite color-combo.
Westie sure does look good! Not only will we now be able to easily spot and trace all leaks of oil, water, or coolant, our engine also now has been given a few more years of rust-free health that we hope to continue. Brandon recommended after we run the engine for 5-6 hours once we’re back in the water, which will give it time to “burn the paint off,” that we then spray the whole engine down generously with anti-corrosion to continue with our rust-prevention plan. It will feel good to know we’re taking steps to proactively fight the rust down there.
But, one word on our prep, in case any of you are planning to paint your engines too. We did not prep near enough. While we did cover everything in the engine room that we did not want to be forever converted to Westerbeke red, and we did drape what I felt like were an exorbitant amount of sheets around the engine area, what we failed to do was successfully contain the red dust that fumigated from our engine room while we were painting, the entirety of which traveled all over the boat. Read that again.
All. Over. The. Boat.
Look at these photos here. I have circled the areas that are coated with a pink dust.
When we finally pulled all of the sheets and looked around, the entire boat, going forward to the bow, had a fine layer of pink dust on it. Thankfully—knock on a freaking jar of acetone—that stuff dries so quickly that by the time it was airborne and ready to drop, it was merely a powder that could be wiped off of the floors and acetoned off of the gelcoat.
Meaning, we did not permanently stain our entire boat pink for good. But, we should have done a much better job of somehow “caging” the entirety of the air around the engine room. Perhaps with more sheets taped over and above, or plastic drop cloths taped all around. I’m just pontificating here because we sure did not contain it enough. We probably should have had better ventilation to pull the “red air” directly out of the boat through a lazarette and draped and taped that exit hole as well. Thankfully, while we were able to remove the red by wiping the wooden floors with a wet rag and all of the gelcoat inside the entire boat with acetone, this did not make it an easy or quick job.
The fans, in particular, took a while to clean because they pulled so much “red air” through them.
You can see in this photo the red sheen on the gelcoat. Each section like this—particularly the sections that were textured like nonskid—took about 15 minutes to wipe clean. We turned twenty rags red just from wiping our boat down after our poor prep job for the engine paint.
The good news is, we had planned to wipe her down regardless—bow to stern—as we always do when we have all of the soft goods out. So, this wasn’t too much of a setback for us, but definitely an extra day of cleaning we added to our own list by not covering as much as we should have for the engine paint job. But, lesson learned for sure.
Our engine paint project, however, did not stop with painting our engine. We had planned from the start to also add bright LED lights in the engine room after we completed the painting and replace our old engine room insulation, for several reasons. One, our old insulation was all rag-tag, duct-taped-on in multiple colors and always falling apart, crumbling, and making a nasty black mess every time we accessed the engine.
We primarily wanted to remove it because it was filthy. And, two, we were sure in that crumbling condition it was not performing at its optimal heat-and-sound buffer capabilities. We also wanted to install engine room lights so we would have excellent visibility in the engine room without having to hold flashlights in our teeth. (Okay only Annie does that, not Phillip, but I would like to break the habit.) The entire goal with this mini-engine overhaul was to make our engine run better, cleaner, and better enable us to work on her, troubleshoot, spot leaks, and repair issues underway. So, cue the lights!
Phillip installed one on the front of this bulkhead over the engine, as well as on the back.
We also installed a third, larger one, that runs bow to stern, rather than athwartship, in the engine room itself behind the engine. Phillip was sure to install them all in a way that the “on” switch can be reached from our easiest access point, the front of the engine in the galley. I can’t show you the big one in the engine room, yet, because it will ruin the NASA insulation reveal. Savor the intrigue!
For the insulation, we ordered four boxes of big thick rolls of Soundown insulation from the internet along with their sealing tape, and this became an exclusive Annie project.
While some of the pieces were easy to template, others were not. These pieces under the sink were rather large, and mostly square, so I started there, with construction paper templates first, then cutting pieces out of the insulation.
This monster, though … I can’t tell you how many days at the shipyard I found (mostly legitimate) reasons to avoid starting on this wall. With all the wires and mounts and stuff, it seemed impossible to template. It was hard enough to rip the old insulation out of there, much less make a precise pattern to put new insulation in.
But, a project will never get done if you never start it. So, I bucked up one morning and set to it, first with construction paper taped together to (in hopes) make the entire piece out of one template. This was my awkward masterpiece.
I had no clue if it was actually going to squeeze in behind the small gap in the gadgets and wires I had created to work construction paper through, but Shane and I gave it a shot. His words as it slid into perfect position: “I’m going to lose my damn job!” : ) That was a really cool feeling for me. Never had I done that before, but I’m confident I can now lay down engine insulation with the best of them.
But, that was just the initial “mounting” (I will call it) of the insulation to the bulkhead with the 3M 77 adhesive spray. The tedious and very time consuming “seaming” of the insulation is what had me down in there for hours upon hours. Shane told us the trick to keeping this insulation in good shape is to prevent any water entry into the foam. You do this by tediously taping every exposed foam seam. This often takes layer upon layer of tape (much link shingles) to get the tape to push the foam down, wrap, and hold. Let’s just say I went through a lot of tape. We also secured the insulation with screws and fender washers, and I was tickled platinum pink with the results. Our engine room now looks like a NASA launch pad.
And, what do you see there? Our new 21” LED light in the engine room. Lighting up the insulation like a Christmas promenade. It is quite the dazzling display down there now. Westie feels like a show horse at the County Fair. I feel bad for any drop of oil that even thinks about inkling out of our engine. Like a prisoner trying to escape from Alcatraz, we’ll shine a spotlight on it so fast he’ll run back to where he came from and never come out again. There will be no leaks from this engine people. Nada.
Hope you all enjoyed the engine projects. Guess what’s next! Our swap to a composting Airhead. That became a bit more of a puzzling project than we had initially anticipated. Trust me, all of this weirdness will make sense soon!
What do you think I’m installing here? Give it a guess! And stay tuned!
Many props to our prop for hanging in there with us for so long (even though we were blind to her suffering!). We’ve been battling this problem for several years now and simply did not know what the underlying problem was. We did not know the “key” to the issue was the fact that the key kept coming out. Here’s what we were dealing with:
Our prop shaft and coupler both have a matching notch that fits a key which helps the shaft sit tight in the coupler so it can be rotated smoothly by the transmission. You can see the key here.
Yes, the one with the red goop all over it. That’s Loc-tite, what we thought would be the answer to this problem. You see, this key kept coming out. Phillip and I are pretty diligent (we try to be, at least) about checking on our engine. We always check the oil, transmission fluid, and coolant levels before starting. And, if we are motoring for a significant number of hours while underway, we try to make a habit of pulling back the sink (which gives us access to our engine) and checking on Westie as he is motoring along hour after hour.
We look for oil or coolant leaks, water leaks, any loose parts, etc. And, during our trip down to Cuba and our fantastic sails back up along the coast to Pensacola in early 2017, we noticed this key kept coming out.
Often we would find it halfway out, spinning around like a wild tea-cup ride at Disney, as the shaft was spinning. Or, we would find it spit out about six inches forward of the transmission into the bilge. Phillip and I would start to wager bets as we would be trucking along under motor and heading down to check on the engine: “Do you think the key is halfway out by now, or already spat to the bilge?” (Most times it was already jettisoned by the time we checked.)
Phillip and I knew this key issue was a sign that some bigger problem was likely the cause and that there was something going on that wasn’t right with our coupler or shaft. We just did not know what. I can’t tell you how many times we located and re-Loc-tited that sucker back in place. Dozens, if not more.
While this little key popping out might seem like a minor problem, we were worried, if it continued or worsened, the transmission could potentially lose the ability to turn the shaft. That would be a huge problem. So, the key was legitimately discerning. Our first thought was to have a new key machined that stuck out a little further past the end of the shaft, with a hole drilled through it, that would allow us to run some seizing wire through it to prevent it from coming out. That would solve the problem, right?
If that was the root problem.
As we continued cruising, to the Bahamas this past season in 2017-2018, and watching further changes occur with our prop shaft, we soon learned it was not.
Our first discovery: There’s a set screw for the key!
I’ll just have to admit, we did not know that. For whatever reason, each time we were checking and re-hammering in this stupid little key, we just didn’t see it, or if we did, we did not know it was a set screw for the transmission key. So, “Aha!” Moment No. 1 was making this discovery, finding the set screw had indeed rattled itself far too loose, and re-tightening him down onto the key to hold it in place.
And, of course, we goobed that guy up with red Loc-tite, too. That seemed to be our solution for many boat problems at the time. “Just Loc-tite it. It’ll never come loose.” Right, cause that’s how it works on a boat. Nothing ever rattles. Nothing ever breaks free. At the time, we were using the same method with the three nuts on the back of our rudder post cap underneath the cockpit floor and you now know, from our rudder post reinforcement post, we have since come up with a better-than-Loc-tite solution there as well.
When the set screw, much like the key had, started to break free from its repeated Loc-tite baptisings and allowed the key to continue to spin out, we knew we were going to have to do something else when we hauled out in 2018. At the time, machining a new key was the best conceivable answer. And, in the meantime, we just continued our “locate and Loc-tite” drill to get us back from the Bahamas to Pensacola to really troubleshoot and solve this issue.
But, then something funny started happening. Not only did the key continue to drift forward and come out. Toward the end of our Bahamas voyage, the shaft itself began to move forward. Yes, the shaft. This is not the best angle, but in this photo it is sticking about an eighth to a quarter of an inch out.
This movement of the shaft itself (not just the key) prompted Phillip and I to inspect the coupler further. We found the set screws on the coupler had also rattled themselves a bit loose, so that the coupler did not have a good tight grip on the shaft. Phillip tightened these down. This was during out trip back up the west coast of Florida on our way back from the Bahamas. And, to get us back home to Pensacola so we could haul-out and investigate this further, for good measure I cinched them down with seizing wire.
At least I thought I did. Turns out I’m not the best cincher. Or maybe it would be seizer … I’m sure I’d make one helluva Ceaser! But, knowing what I now know about how to run seizing wire (which I just learned from the boys at the yard – thanks guys!) I know this is a total useless loop. Hell, that design probably helps both screws loosen one another …
Way to go Seizing Wire Annie. Thumbs down. But, I can confidently say my seizing skills have since improved after we got a custom lesson from the boys at the yard. This is why we love working with them. I’ll show you the trick when we get the coupler issue figured out.
Cue the haul-out!
When the boys at the yard got their hands on our boat, they noticed several things immediately that were adding to our issues with prop shaft movement. First, they could feel and, actually with their hands alone, re-create the forward and backward movement of our prop shaft inside the coupler. Again, not the best quality video, but it was sent to us from Shane at the yard and you can easily see the movement of the shaft in and out with just Brandon below pushing and pulling it.
This was their first cue that something far more serious was going on with our prop shaft than a loose set screw on the transmission key. The boys could also feel that the strut had a little play in it, as they could physically move it from side to side—just a hair, but hairs can make a mess out of things offshore. They recommended it would be best to remove, clean, and rebed the strut for a more secure fit to the boat and tighter hold on the prop shaft.
That was a fun morning I spent unbolting that guy. Can you find the Annie in this picture:
Thankfully, I will say, almost every single part of our boat is accessible. While it may be uncomfortable and require the talents of an inconceivable contortionist, it is reachable. We can access, remove, and repair just about any part of our boat, because it was designed to do just that—be accessed, removed if need be, repaired if need be, and otherwise worked on! It’s one of the very great features of our boat. I was happy to find our four strut bolts were (with just a smidge of boat yoga) rather easily accessible right behind Westie on the engine room floor.
The shipyard guys, when they disassembled the strut, also noticed our cutless bearing was worn out. While this surprised Phillip and I as we had replaced that cutless bearing only a few short years ago in 2014, if you consider the amount of play we had in our prop shaft, and the number of miles we put under our keel while that play was occurring, it made sense.
Lastly, when Brandon removed our coupler, he found the coupler itself was wallowed out with the movement of our shaft and it simply (tightened down its full capacity) could not get a good grip on the shaft.
When Brandon removed both the prop shaft and the coupler from the boat, he showed us the movement he could exert with his hands on the shaft. Brandon explained the coupler should slide on and have an absolute snug fit with no movement. He and Shane also said we were lucky the shaft was going forward. This happened when we were in forward gear because the propeller is trying to work itself forward through the water. If we had backed down hard enough in reverse, the prop would have been working to move itself backwards through the water and could have worked its way right out of the boat with the condition our coupler was in. Now, I have a new boat nightmare. Thanks boys.
Here is a video of Brandon showing us the movement in the coupler and having fun at my expense. You will be surprised by the play in our coupler. You can hear it audibly in the video. You’ll also enjoy Brandon’s response to my joking that he had “purchase discretion up to $800.” “Oh, it’s $799 then. $799!” Gotta love those guys at the yard.
So, with this revelation, we were in for a re-bedding of the strut, a new cutless bearing, and a new coupler. But, if we were going to replace the coupler, we wanted to re-engineer it so the coupler would not allow the key to come loose or the shaft to try to move forward again after the many more miles we plan to put on our boat. For this reason, Brandon hired a local machinist to create a cap that bolts onto the end of our coupler to hold the shaft in place. He kept a window hole in the cap so we could see the shaft and visibly confirm its location in the coupler. The machinist also included a threaded hole in the center that we could use to twist a bolt down to pop the shaft out if it had, for whatever reason, seized up in the coupler. Overall, it was a better, stronger design for our boat and eliminated all movement in our prop shaft. Here is the new coupler!
And, fun little lesson for all you boat project fanatics today. Notice Shane’s method for fastening seizing wire in the photo above. While everyone can do it differently, I definitely liked his idea of purposefully routing the wire in a way where one bolt’s attempt to unthread and turn to the left would result in a tug on the other bolt toward the right, and vice versa. Meaning, as the bolts try to loosen themselves they are, in fact, tightening one another. Thanks Shane!
Little things like this can make all the difference out there on a two-week passage where you are working all systems so hard twenty-four hours a day. Phillip and I know we will sleep better and have more peace of mind knowing this system, too—our prop shaft, the coupler, the cutless bearing, and the strut—have all been inspected, re-mounted, secured, or re-engineered to be stronger and more stable for our rough passages.
This is the reason Phillip and I decided to devote the time and money this summer to haul-out and do these “mission critical” repairs and upgrades as we have some big cruising plans this fall. And, some big destinations to announce! We can’t wait to share our plans with you (you know, the ones written in sand at low tide ; ). But, next up, we’ve got some more cool shipyard projects to share with you. Hope you all are enjoying our boat labor this summer! You get to pick next week’s topic. Because:
I can’t make heads …
… or tails of it!
Would you like to see our swap to the composting head or re-painting of our Westerbeke engine. You decide. Leave your vote in a comment below!
Maybe they should change that B.O.A.T. saying to “bonded or about to.” I’m sure many of you have faced this. One of the hardest parts of a boat project is the initial disassembly. Trying to get bolts that have been in place for thirty-plus years to budge. Or how about a stainless steel bolt in an aluminum piece? I know you’re cringing now. But, at least I can say we had access to our curmudgeon bolt. I had a follower post recently in order to get to bolts he needed to access to re-bed his strut, he had to remove two diesel tanks. Just to GET TO said belligerent bolts.
Shout-out to follower, Rob Miller, who tacked that job! Rob, you’re my hero. In our case, with access, albeit uncomfortable and tight, to our bolts, I’ll consider us on the lucky side. Here’s what we were dealing with. These are the components of our rudder/steering system:
The quadrant (which is in two half-circle pieces) mounts on the rudder post by fitting onto that slotted “keyway” mentioned in the diagram, and it is then bolted together, four bolts at the base, inserted in opposite directions, which thread into opposite piece of the quadrant. You can see here, the two bolt heads on port (your right) and the two holes that the shafts of the bolts on starboard are threaded into.
We knew in order to drop the rudder we were going to have to get these two quadrant pieces apart in order to remove the quadrant so the rudder post could be lowered. For this reason, Phillip had the idea to spray (well, I should say Phillip had the idea to send his bendy grease monkey down in the lazarette to spray) PB Blaster on the four bolts under the quadrant periodically for a few weeks before we hauled out hoping that would help loosen those suckers.
But, as many of you know, when you allow two different metals, here stainless steel and aluminum, to sit together for years upon years, the metals can undergo a chemical reaction and literally bond themselves together. When the boys at Perdio Sailor got in there, that is what they found. The bolts holding our quadrant to the rudder post had thoroughly seized.
With Brandon in the starboard lazarette (which stinks, that one is super tight and uncomfortable) and Shane in the port lazarette (which is a bit more spacious, but not as much for a 265-pound guy), the boys made several attempts to get the bolts to budge. First they tried manually.
Then with a cheater bar. Then with the impact driver.
Then with heat (lots and lots of heat) followed by the impact driver.
Thankfully, three of the bolts finally gave up the ghost with heat and impact and came out, but we had one last stubborn holdout on the port side. The boys continued to battle it with the impact driver, then heat, then impact, then cursing. Still nothing. More heat, more impact, more cursing. No movement. Shane finally dropped his wrench and said “I’m cutting it out.”
Breaking a Bonded Bolt
I’ll be honest, I didn’t exactly know what “cut it out” meant, but watching the guys at the shipyard—who have to deal with obstacles like this every day—think through a problem and engineer a solution is the exact reason we like to haul-out with Brandon’s exceptional team and learn from their thought-processes.
Shane’s idea was to cut the bolt head off, so he could at least pull the two quadrant pieces apart and remove them from the boat.
Then he could try to drill into and perhaps extract the obstinate shaft or, if that would not work, he could drill the shaft out, enlarge all four holes slightly and either re-tap them for new bolts, or go with through-bolts instead. Shane chose the latter and we now have four bigger, stronger, more-secure bolts, locked down with Nylocs, holding our quadrant on the rudder post.
And, it was educational for Phillip and I to learn how the crew at Perdido Sailor work around, what might seem to us, an insurmountable obstacle. You’ll also notice Shane really cleaned and spruced up our thirty-three year-old quadrant.
Thirty-three … pssssh. That pretty gal would get carded in bars. “Can I see your ID Ma’am?” : )
Proof TefGel Works
In addition, to ensure this unwanted bonding did not happen again (because you never know, we might need to remove the quadrant again someday down the road), Phillip and I used TefGel during the reassembly to ensure, this time, the stainless steel bolts did not try to bond with the aluminum quadrant.
Our tiller arm served amazing proof of the power of TefGel to prevent different metals that are in contact from bonding over time. Phillip and I installed our below-decks hydraulic auto-pilot (which we lovingly call “Lord Nelson,” because it came from a Lord Nelson boat) back in 2016 when we were hauled out to repair our rotten stringers under the mast and replace the rigging. In order to remove the rudder from the boat, the tiller arm also had to be removed. This is the bronze tiller arm mounted above the quadrant.
And, although the arm had been in place for two years untouched, with TefGel in the mix, the stainless steel bolts that hold the bronze tiller arm on the rudder post easily unthreaded. Proof: TefGel works people. Use it!
Alright, one problem solved. What’s next? Alignment of our steering cables!
Re-Aligning Our Steering Cable Pulleys
When Brandon first crawled down into our lazarette to inspect the quadrant and steering system, he noticed immediately that the alignment of our steering cable pulleys to the quadrant was not ideal. (Even though the cables are off) can you see what Brandon saw in this photo?
The base of each steering cable pulley was about one-quarter to one-half inch lower than the “seat” (the center of the groove) in the quadrant for the cables.
This meant our cables had to travel uphill to fall into the seat of the quadrant. Not something you want them to have to do.
It should be a perfectly-aligned straight shot from the pulley right into the seat of the quadrant. All of these years, and I hadn’t noticed that.
Just another reason we love having professionals, like Brandon and his team, crawl all over our boat looking for potential issues. “Look in every locker! Check anything you want! Sure, wiggle it. See if it works.” I say that because we want the Perdido Sailor guys to find anything they can that needs to be fixed while we’re in the shipyard. And I stress “need” because there is a time and money factor; no boat is going to always be in 100% pristine condition. But, we want them to find problems while we’re in the yard, because that’s when we want to fix them—when he have great tools, supplies, and experts readily available to help and supervise, rather than finding the problem when we’re out there underway with less resources and knowledge to devote to it.
And, the joking and ribbing that goes on at the shipyard is just part of the fun. Here, Phillip had missed the measurement of the additional height we would need to be jacked up in order to drop our rudder by just a couple of inches, and the guys never let him forget it. If you don’t do it absolutely 100% perfect (because we all do that, all the time, right?), they’ll pick on you. But, the more they pick on you, the more they secretly like you. Shipyard Fact No. 64.
When Brandon saw the steering cable issue, he had the idea (since he knew we were dropping the rudder which would mean the quadrant would have to come off) to lower the quadrant just a bit to make it line up better with the pulleys. I immediately laughed when he said it. Just as a knee-jerk reaction, because I knew how very little room we have between the quadrant and the aft strut. How do I know this? Because I saw that tiny little space disappear one exhausting night in a beat-down underway when our rudder had tried to make a sneaky exit out of the boat.
That was a fun night. And, a fun little video for you here of our quadrant literally grinding its way into the aft strut that supports the post, why it happened and what we learned the very simple remedy was: tighten the cockpit nut that threads the shaft up higher into the boat.
But, lack of space between the quadrant and the aft strut in order to properly align the quadrant with our steering cable pulleys did not hinder Brandon either. I swear, they don’t see obstacles, they see solutions taking shape. And Brandon certainly had one here:
Cut it. Re-engineer it. Make it work better. You gotta love that guy.
Brandon had his main guy, Shane, modify the aft strut by cutting a nice even chunk out of it that would allow us to mount the quadrant back on the rudder post at a lower spot to make it align perfectly with our steering cable pulleys. Here is a video of Brandon checking Shane’s work after Shane and I reassembled the quadrant for inspection:
And, do you know what “get in there and square that up a bit” means? Another disassembly of the quadrant by Shane and I to finalize the cut and sand it out, then reassemble the quadrant and steering cables …. again … to make sure everything worked and operated perfectly. I’m telling you, by Day Two at the shipyard, I am quite confident I could disassemble and reassemble everything on the rudder post myself. What an awesome confident feeling!
But, it will all be worth it when our quadrant now has free space and no chance of making contact with the boat if it the cockpit rudder nut gets a little loose in heavy seas (although Phillip and I now know to check and occasionally tighten that nut), and our steering cables are no longer having to step up to fall into the seat of the quadrant. Now they are perfectly aligned. Little things like this I’m sure will add years of awesome cruising years to our beautiful boat. And, while we continue to learn the more we work on our boat, I know she still has many lessons to teach us. And, I know we’ll be ready to learn them, whether they occur at the yard or out in the big open blue. It’s a great big school out there!
I know some days will look like this …
But many others will look like this …
And I wouldn’t have it any other way! More shipyard projects to come. Next up. We’ll give props to the prop shaft by re-bedding the strut, replacing the cutlass bearing, and re-engineering a new coupler. Stay tuned!