Forever boat: bigger upkeep on an older sailboat

21 Nov
Two girls petting a dog in front of a marine travellift with a sailboat in the slings.

  

Jamie and Salvador talking about work to be done on Totem

  

Totem turned 36 this year. We treat her like our forever boat, and prioritize maintenance to ensure our sailboat / home remains a sound vessel with a long future ahead. Lately that means turning attention to a projects that accumulated into something more than “routine maintenance.” While organizing plans for the new bottom (we’ve made a decision on bottom paint, by the way, details coming soon – I am VERY excited about our plans, details coming!), a number of these kicked off.

Step one is simply getting supplies. Some things are easy to get in Mexico; others aren’t. Because Cabrales Boatyard is only an hour and a half south of Arizona, it’s not hard to source from north of the border. There’s even a West Marine in Phoenix! Several other cruisers in the yard are making trips back and forth; we’ve been able to tag along with road trips to get our supplies down, and our friend Michael (my co-author for Voyaging with Kids and Good Old Boat editor) has provided invaluable mailstop support from his home in Arizona, and Pam Wall helped secure good prices all the way from Fort Lauderdale. (Rhetorical question: is it still cruising when you can get an Amazon Prime order?)

While waiting on materials to get the bottom done, Jamie’s tackled power train work. The engine mounts are probably original to the engine; Totem was repowered in 2002.

Old and new, side by side: I think it’s time, what do you think?

Shiny new engine mount in front of a well worn older one

Propeller shaft woes: it’s original, but that’s not the problem. Unfortunately, it seems that it wasn’t sufficiently protected during blasting to remove all paint from the bottom in Grenada last year. The little bit of grit that got inside was enough to cause wear in the shaft in the subsequent miles: that’s gotta go! Jamie’s ordered a new shaft made from Aqualoy 22. I’d never heard of Aqualoy, but it’s an alloy specifically designed for marine environment applications: corrosion resistant and stronger than the comparable grade of steel that would be used for the shaft. That sounds like an excellent “forever boat” choice.

man holding cut-off propeller shaft
cut-off prop showing damage from the area inside the two bearings

 

cutting off the prop shaft
Honestly I’m happy I didn’t witness this (Siobhan’s photo)! Jamie: “The angle grinder paid for itself today.”

Remember that steerage failure off Colombia? We’re replacing the failed chain, but instead of a stainless cable we’ll use Dyneema. The fix Jamie put into place 4,000 miles ago has proven itself. Additional work on the steering system includes replacing sheave pins and bearings: bushing from Oilite (a bronze alloy) will replace the old bearings, providing lower friction. After 36 years, the stainless pins showed wear, so those will be replaced as well.

Jamie holding two steering cable sheaves in dirty, work-hardened hands
Some see the sheaves. I see hands of a very hard working boat dad.

 

Up at the bow, we’ve long wanted to repair the anchor rollers. They are TOASTED and have been for some time, but the right size rollers never seemed to be on the shelf when we passed through better-supplied chandleries. When Jamie saw the machine shop at the yard, he had an idea; improve on off-the-shelf rollers with a slight change in profile that makes it harder for anchor chain to skip over the top. He purchased cylinders of durable plastic stock ordered from McMaster-Carr (love this resource for boat bits at non-marine-markup prices) and is having the profile machined to order.

Salvador and Jamie squatting on the ground with materials and plans for anchor rollers
Jamie and Salvador making a plan for the anchor roller

 

Plastic stock for future anchor roller, plans sketched on paper, and beat up old roller.

 

Three men confer inside a well used machine shop
Salvador communicating direction for the machine shop crew

The bow pulpit needs attention too. Like many boats built in the 1980s in Taiwan, mixed quality stainless steel was used for everything from tankage to stanchions. Bit by bit we’ve addressed original stainless components; it’s the bow pulpit’s turn. The feet are cracked. It’s not imminently dangerous, but time to replace, and the skillset and resources are here to do the job at a reasonable rate.

Totem’s swim ladder is another piece of original stainless being improved by the welders at Cabrales Boatyard. The support legs which help our swim ladder stand off Totem’s transom when deployed make for pesky obstacles and chafe risk when raising our dinghy on the davits. It would be nice not to have to finesse that process every time we haul the dinghy and eliminate the risk so those blunt legs have been replaced with a gentle curve that will function much better, and be kinder to the dinghy.

The bare fiberglass bottom is also a great opportunity to clean up Totem’s through hull scene. We replaced most of the  36-year-old seacocks in Thailand five years ago, but a few of the originals  remained. Instead of replacing them, Jamie’s removed them. Each divot left by a former through hull is now filled with a large sandwich made up of layers fiberglass and epoxy.

How did we manage to eliminate so many through hulls? Well, one was unused. Two were sink drains which will now drain to a greywater system in the bilge. The fourth is a raw water intake for a toilet, which will use water from a greywater system instead of seawater.  We’re happy to minimize holes in the boat, and pleased to have just five for a boat of Totem’s size and layout.

One project that’s more of a luxury item than upkeep of a good old boat is our plan to expand solar charging capacity. Solar power keeps getting more affordable: quality panels are about $1/watt, and we had an opportunity to buy gently used solar panels at an irresistible bargain. A pair will soon come down from Arizona and we’ll increase our capacity from the current 270 to about 650… cost to us about $0.37/watt. SWEET! OK, so it will cost a little more because we’ll need another charge controller: still feeling very good about improving our green power generation.

Meanwhile, Totem looks like there was a small Stuff explosion inside. We had a lot of fine dust to clean out after the summer on the hard: bits that filtered in through solar vents and other crannies. 

Looking down into the main cabin where tools and gear spread on table, bench, settees, and cabin sole

The state of chaos is a sinusoidal wave between “messy” and “chaos” that won’t improve dramatically util projects are done and we’re on our way. That’s OK. The work getting done right now feels really, really good: important steps to ensure the long future life of our floating home.

Masts and rigging from boats in the shipyard are silhouetted by a vibrant sunset in Puerto Penasco

This article was syndicated from Sailing Totem

Comments

  1. Kim Marc

    This is a great article; very nicely written about real (boat) maintenance situations and great solutions. Please keep the posts coming. Thanks and good sailing.

  2. Jamie Gifford

    Hey Chris! Our shaft issues was two-fold. #1 is age. #2 when we sand blasted the old bottom paint accumulation off, they did (and I didn’t think about it at the time) protect the cutlass bearings from getting grit inside. After the job, I recognized the issue and flushed and flushed and flushed to get any residual debris out – but, I’m sure this contributed to wearing enough to be outside of diameter tolerance at the bearings. If you’re not sand blasting, you should be fine. If you are, wrap the shaft so that debris cannot get into the bearing… Our new Aqualoy 22 prop shaft just arrived – it’s very shiny!

  3. Jamie Gifford

    Hey Jim! Dyneema has great chafe resistance – for line, but not as good as stainless steel. However, stainless steel has plenty of issues – and fails far more often than any other material on Totem (probably the case with many cruising boats). Pros/cons to everything. As for Dyneema steering cables – they are NOT for everyone and probably not for most. There are some special considerations in setup: ensuring there is no chafe (easy enough to figure out), ability to monitor and retension after initial constructional stretch of Dyneema (Dynex Dux is better). We’ve done 4k-ish NM with Dyneema steering cables and want to test further. They may prove a win or a fail or a great temporary solution. We’ll write-up the process and findings.

  4. Chris Woodward

    Another great article and photos on boat life/maintenance. Thank you. Any suggestions for someone approaching a bottom job a the same yard in Grenada to avoid the shaft corrosion issues you encountered? On another note, I’d highly recommend the Outback Systems solar charge controller!

  5. Jim beer

    Hi, there was recently an article here in sailfeed by a surveyor who pointed out that dyneema is not chafe resistant and should not be used in steering gear. Also please never use the word “skillset”. Just my opinion. Love your articles. Jim Beer in FL

  6. Behan Gifford

    hi Gregg! we’ve had no problem at all with crossing at the Sonoyta border, other than almost forgetting to get tourist visas when we arrived. It’s a ‘free zone’ where for a limited time (72 hours?) no visa is necessary, since there’s a fair bit of tourist traffic that flows back and forth between here and Phoenix (about 4 hours away). Several trips with goods from West Marine etc., no issue at all.

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