New Zealand Boat Projects

05/01/2005 - 10/01/2006

Between May 2005 and October 2007, we accomplished (or paid others to do) a significant amount of work in preparation for the 2008 cruising year. Whisper is now eight years old and by 2007, she was ready for some minor maintenance and repairs, as well as some more serious cosmetic work to her decks and topsides.

In May 2006 we had a haul-out for bottom repairs, thru-hull/seacock work, and bottom paint. In July 2007, we hauled out again for another thru-hull replacement, some rudder repairs, bottom paint, and a bunch of cosmetic work. Since work consumed our weekdays, these projects were handled by Oram's Marine with Barry Richmond supervising the work. We were happy with 95% of the work. On the second month-long winter haul-out, we took the opportunity to live in an apartment in the Viaduct.

In between these two major haul-outs, we had a considerable amount of additional work done -- or we did it ourselves.

Of course, a 200 line Excel spreadsheet helped manage all of this -- with task / project scope, priorities, and cost estimates (labor and parts), along with a schedule, and a rough plan.

Whisper in the travelift on one of our two Auckland haul-outs.

Whisper's bow when in the sling.

The Max Prop before cleaning.

The Max Prop after cleaning.

After almost eight years with nothing more than mop-washes with soap and a light solution of bleach, the erosion of the teak is significant enough to consider the first sanding of the decks.

The cabin-top before sanding.

The dodger-top before sanding. All the now "raised" caulking needed to be hand-trimmed with sharp flexible knives before starting sanding.

The deck after sanding. Orams was asked to only take off one millimeter or so. They did a good job.

Just after a rain and they look good as new.

The aft deck.

The dodger looks good again too.

After the sanding, several teak screw cover bungs popped out, but they are easily replaced. The original screws were not counter-sunk deeply enough. It takes Duncan about 10 minutes per bung to replace and he has already replaced about 15 of them in two batches. No additional bungs have popped recently, so we hope we have them all for this round.

With good maintenance, the decks should go another eight years until they need their next 1mm of light sanding.

Another issue was our fading paint-stripe around the cockpit coaming.

Orams re-painted this, but they needed to do it twice because the weather caused the first round to somehow fail. It looks fine now. We acquired the new decals from Hallberg-Rassy.

When the boat was out of the water in 2006, we found this issue with the fiberglass. It came loose from the bronze gudgeon shoe on the rudder skeg.

No problem. Grind it down and replace it with fresh glass.

Looks good.

In 2007, we noticed the seals that prevented the ingress of saltwater up the rudder post had failed. These "simmer" seals occasionally fail and need to be replaced. It was a project to get the old ones out and the new ones on! The can be replaced with the boat in the water and without dropping the rudder, but doing it while hauled out was a good time to do it.

Two leaking thru hulls and seacocks warranted replacement. One was a factory install and the other was installed during the first outfitting. This is the outfit install. We up-sized the backing plate and the thru-hull/seacock in attempt to help the generator's water separator more effectively separate water. That didn't help , but the new thru-hull is great and doesn't leak.

It's quite normal to get separation cracks between the lead keel and the fiberglass-hull. We try to keep them sealed and painted the best we can, allowing for some flexibility on the seam.

The gelcoat repair done in Tahiti finally failed. Orams recommended we fix this with paint. Not sure if this was the best long-term solution, but it sure looks better now. Time and UV will tell.

Whisper's varnish needed another touch up. Exterior varnish work was done by Orams as well. This is the 5% of Oram's work we believed could have come out better. The varnishers insisted on booth spraying everything. Some bits came out fine and others will need to be redone in the near future.

Each of the large hatch trim-rings was refinished because UV and sunshine resulted in the old varnish/lacquer starting to chip. Spraying varnish on the interior was awkward and didn't necessarily achieve a better result than brushing.

Overall, Whisper looked great after coming out of Orams in 2007. The full cut and polish and waxing helped spruce her up as well.

The old Lifeline AGM's in the port battery box. One of the major headaches on our last cruise was battery performance. In 2007, we replaced the Lifeline AGM batteries with equivalent Toyama Gel/AGM hybrid batteries supplied by Enertec here in Auckland. So far, the Toyama performance for price ratio looks good.

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We have seven Group 31 batteries in a split bank. This was the starboard-side bank with Lifeline batteries.

Replaced with the Toyamas and re-wired as required.

The terminal post configuration was not exactly the same, so minor wiring mods were required.

We also replaced the engine start battery.

When we went to the battery recycle post at the marina, 80% of the batteries in the scrap pile were Lifeline AGMs. Anecdotal, of course, but it made us chuckle.

Robin and I marked our first batch of new PWB-L anchor chain. Below you will find the whole sad (and expensive) story behind the replacement of this nicely marked chain with 100 meters of entirely new chain and a new windlass gypsy.

Done with the marking, isn't it pretty? Much of this outdrive paint wore off after only a few uses. Maybe we need colored galvanizing?

Orams re-galvanized our 60LB CQR anchor.

When the windlass, gypsy and chain work well, life is good.

When they don't, it can be quite frustrating and exhausting (lifting 100 feet of chain and a 60lb anchor manually).

The new allegedly Australian made PWB-L chain split the Lewmar Ocean 1 windlass 003 gypsy -- even though this is supposed to be the correct combination of gypsy and chain.

It happened twice and when we checked, the chain only fits into the gypsy if there is no load on the chain. Brilliant.

After much troubleshooting and frustration, we ended up with new chain and a new gypsy. The old chain sold on the auction site for one-half what we paid for it.

Every few years, we need to get our liferaft serviced.

This was our second servicing, but since there is an authorized Winslow repacker here in Auckland, Duncan got to go along and watch the initial inspection and inflation.

Gently unpack form the valise and unroll.

Slowly manually inflate. Perhaps this is to reduce possible damage caused by sudden inflation.

And that's what it would hopefully look like if we ever needed it.

The old flares, provisions and water were all expired.

The air bottle needs a visual and hydrostatic test, a fill, and a new firing head pin, spring, and washers. We retained the old parts so we could see what they look like and understand why they were so expensive.

These little inflation tank firing head parts were $195 NZ ($174+GST). If it cost hundreds of thousands to engineer and it's precision crafted using the highest-grade stainless steel, that might explain why such a small item cost so much? Ouch.

Even this new label cost $160 NZ ($142+GST). Not sure we can explain the cost behind this item?

All repacked, $1500 NZ (~$1000 US) later. Initially, we felt the cost was high -- then remembered we paid over $2200 US back in 2003 (while cruising in Mexico) to get it serviced back in the states. The cost of the NZ Winslow service seemed reasonable!

Two major rounds of work was done on the Fischer Panda genset. Of course, the exhaust elbow failed again. We go through one per year and budget accordingly.

The Panda exhaust cooling mixer elbows consistently failed on the weld seams. Usually just pinholes at first, until they corrode into larger holes and eventually fail the entire weld ring. Duncan caught and replaced this one before catastrophic failure.

The Panda heat exchanger is also corroding and will probably fail soon. It will be expensive to replace, so we are procrastinating on purchasing a replacement until this one completely fails.

The Panda water pump started leaking in several places where it should not. We had the old replaced-once-already spare pump re-built and all is good again.

We discovered the Volvo main engine turbo charger had failed on our crossing from Mexico to the Marquesas. We just got around to fixing it in 2007. We replaced it with a new turbo-charger, replaced the "serpentine" belt, and serviced all four injectors.

In addition to having a rigger inspect everything twice, Duncan got up the mast to replace the deck floodlight. He still needs to go up again to complete the running backstay anti-chafe project and to cable-tie up the top-of-mast wiring harness.

The old Sony TV/VCR combo was ready for retirement, but Duncan wanted more than an LCD TV...

After much persistence with the budget committee, he finally got approval for the new solution. Now we have a Mac Mini running iTunes / FrontRow as a music, video, photo and DVD server with a matching 500GB LaCie drive and TV tuner (EyeTV 250 PAL TVR).

The second version installation of the Apple Mac Mini (we are now on installation version four) with an integrated TV/Tuner/TVR recorder, a nice Sony LCD on a swing-arm, Cambridge Soundworks powered speakers, as well as an integrated Shinco region 0 DVD player. The Mac Mini can consistently play region 1 DVDs (USA) -- and sometimes region 4 (New Zealand) using VLC -- but it depends on the DVD -- so we still need the Shinco because we have a significant collection of Region 4 DVDs.

The swing-arm enables any viewing angle, as well as access to the cabinet and the media center. At anchor or the dock, we leave it all open and ready to play. For sailing and passages, the LCD is covered with a nice fleece pad, the speakers are removed and stowed in the cabinet, the LCD swings back into the cabinet, and the removable cabinet door slipped back on and closed.

The current configuration when watching DVDs draws about 4-5 amps depending on the speaker volume.

Several times during the set-up of this solution, Duncan felt this solution might be a bit ahead of the technology curve for the average yacht or RV owner. This is just an early adopters version of an awesome solution that many yachties, RVers, and other off-grid 12V users may someday want. Unfortunately, it is a very limited market today. Otherwise, it would have been easier to find (for a sensible price) all the various regulated power supplies, A/V switches, adapters, and video converters we needed. It's all available in high-power consuming 120V/240V home-gear, but there is very little of this technology available for the 12V mobile market. A bigger yacht with a bigger generator would not worry about this so much.

And of course, we "needed" the cool Apple Bluetooth keyboard, mouse, and remote controls. We also added an awesome Harmony 550 universal remote control that controls all of this. Robin did all the programming of the remote, so now Robin is more savvy with the remote control than Duncan!

And when we are underway, it's stowed (LCD padded in it's thick fleece-lined cover), and it's almost invisible except for the external speaker mounts. The Harmony 550 remote also controls the integrated eight-speaker Alpine boat music system (head unit visible above the cabinet -- with amp, subwoofer, and CD changer all installed behind the scenes).

It's time to un-pickle the watermaker. There will be lots of fun work on the watermaker in the coming months because one of the pump heads is (again) failing. We produce less than 9 gallons an hour on two pumps and almost 7 gallons per hour on one, so we are just running on one pump for now. Someday, Duncan will share ideas on what we might (next time) do differently in the watermaker department.

How hard could it be to replace some curtains and shower curtains? Apparently measuring this stuff correctly is quite difficult. After two failures with a local vendor, we decided to order factory replacements from Sweden. When it arrived in Auckland, the shower curtain still didn't fit quite right! After a quick jury-rig (that is still in place today), all is well and the blood pressure has returned to normal.

We also had all of Whisper's upholstery and carpets cleaned. To expedite drying the cushions went on deck.

If this was easy and inexpensive to do -- we would do it every year! Whisper looks and feels new after a thorough cleaning like this.

In the toy department, we recently purchased an inflatable tandem kayak. It stows in a small case...

And inflates into a stable, fairly fast, and decent tracking kayak. We are using it quite a bit and getting even more exercise than we usually do when we're out cruising!

In addition, we also got a new inexpensive laptop for the nav station. We are still sorting our issues with ports and GPS uploads, but 90% is working fine and much faster than the old one.

Our old Magma grill was going to cost almost as much to repair as to buy a new one -- so we did.

The virgin BBQ grill. It doesn't look this new anymore!

We also got away form the disposable bottles and have this cool little refillable bottle now. Someday, we'll need to come up with a more secure mounting solution.

The List

This is a quick list of ALL the work done on Whisper while in New Zealand (excluding the transformer and electrical changes made on arrival and the first round of NZ generator repairs). We did the best we could with the funds and time available and feel fairly good about Whisper's current state. Given unlimited budget and time to do work or to managed project vendors, fewer compromises would have been made. Such is life.

Sails repaired (Elvström & Hasse)

Removed/replaced max-furl battens in Elvström in-mast furling main sail (decided to remove and not to replace). North Sails cut about 3 square meters out of the leech (no more roach) of the main sail. It works great! We don't miss the old roach.
North Sails fixed the leech lines on jib, genoa, and main sail (none would grip in the line-jamb and stay put). On the main, they inserted a mini block and tackle, and on the jib and genoa they did a bungee return. These now work much better than the old jam-cleat alone.

Rig work / up mast

Replaced some of the running rigging: outhaul, boom vang, and other minor lines around deck.
Had the rig checked twice while here. All was well, no tuning required. Minor issues with wire cable-tie, light bulb, and chafing on running backstays. All except deck floodlight replacement still on the anchorage to-do list.

Rudder repairs

Although we performed one set of rudder-related repairs in Mexico prior to leaving for the south Pacific (seawater seeping up the outside of the bronze thru-hull tube between the fiberglass and the outer surface of the rudder tube), we had two more rounds of rudder-related repairs here in New Zealand. None major, just inconvenient and an expense.
The first iteration was to remove and replace the fiberglass "shell" that was coming loose from the rudder gudgeon bronze boot. We had this done in our bottom-paint/prop-service haul-out in late 2005.
The second iteration was in 2007 to replace the "simmer seals" that prevent seawater from flushing up the rudder post/stock and into the boat. These had failed and needed to be replaced. Once the needed parts and replacement instructions were acquired from Hallberg-Rassy in Sweden, Whiting Power's engineering guy did the dirty work that took a full day. Although Duncan might have been able to do it, it would probably have taken three times longer.

Whisper exterior work

Re-painted cockpit coaming blue stripe and replaced HR decals
Fixed / repainted heavily oxidized hull damage area (acquired/repaired in Tahiti in 2004).
Sanded decks (first sanding since new 8 years ago)
Varnished exterior brightwork and some minor interior touch-up
Painted bottom with Micron 66 (did this twice in last two years)
Serviced Max-prop (propeller)
Major gelcoat detailing – cut, polish, wax
Replaced Vetus dorade-vent on bow with newer version that doesn't corrode shut when wet with seawater.

Volvo TMD22-P main engine work

Serviced/Replaced Turbocharger (waste-gate/boost-pump valve corroded shut)
Serviced/Replaced Injectors
Normal periodic servicing and filter changes (every 100-200 hours)
Replaced leaking seawater intake thru-hull and seacock.

Fischer Panda AGT-4000 12V DC generator (genset) work

Replaced exhaust elbow again and resolved frequent corrosion issue on weld seams.
Secured intake manifold (shakes loose every few hours).
Compression checks, check head for cracks, rebuild head and service valves.
Serviced injector.
Troubleshot and resolved the dirty-burning exhaust issue (never determined root cause).
Up-sized and replaced leaking thru-hull and seacock on water separator exhaust.
Cleaned clogged internal oil-screen (not complete because not easily accessible).
Cleaned sound-shell interior of under engine (not complete because not easily accessible).
Replaced inner-casing engine mounts (not complete because not easily accessible).
Normal periodic servicing and filter changes (every 50-100 hours).

Electrical

Replaced the failing Lifeline AGM batteries
Acquired and installed 8 new Toyama Gel-AGM hybrid batteries from Enertec.
Looked into cost and benefit of adding solar panels to Whisper. Will decide whether to do this before departing to Fiji. May do this in Opua before leaving to Fiji.

Safety / Communications

Re-packed and re-provisioned Winslow life raft.
Tested EPIRB and replaced antenna under warranty.
Acquired Motorola 9505a Satellite phone, installed and set up for email and distress calling.
Canceled SailMail, but retained Winlink HF Airmail/Pactor as back-up to SatPhone email solution.

Navigation

Acquired new Lenovo ThinkPad laptop for nav station , set-up and working
Upgraded to latest version of Nobeltec charting software , installed, and working
Acquired Passport charts for Nobeltec for Fiji, New Caledonia and Vanuatu. Installed, and working
Acquired Bluechart charts for the Garmin chartplotter for Fiji, New Caledonia, Vanuatu and Australia. Upgraded old Pacific charts.
Acquired paper charts for Fiji, Australia and New Caledonia.

Water & Plumbing Systems

Serviced Spectra Santa Cruz 380 Watermaker. Replaced broken 2-way and 3-way servo controlled valves. Spares acquired. Troubleshot and fixed low output.
Acquired and installed new forward head toilet (Jabsco large-bowl manual). Dirty job, but someone has to do it.
Serviced aft head toilet, pumps rebuilt.
Bypassed leaking holding tank on aft head toilet. Wanted to remove tank and possibly replace, but required dismantling steering cables and cockpit drain hoses. Expense and hassle-factor put this into the deferred tasks list.

Anchor & Chain fiasco

In November 2006, acquired new "Australian" PWB-L 10mm grade-30 galvanized anchor for the Lewmar Ocean 1 windlass and 003 gypsy. Transported, marked, and installed, and end-spliced into the anchor well.
After first attempts to anchor, concluded something was wrong: chain hopped, skipped, and jumped in gypsy and occasionally jammed completely. Eventually "splitting" the Lewmar Ocean windlass 003 gypsy into halves. Had to drill out screws that secured the halves and replace. Accidentally broke bit and sent remaining drill stub through finger and fingernail. Ouch. Tried gypsy again, failed again at next anchorage. Quit after the second split.
Significant (months of) troubleshooting and diagnostics ensued. Manufacturer of both chain and windlass claim the 003 gypsy is correct for the PWB-L chain, however, despite claims -- it just doesn't fit correctly if there is any load on the chain.
Tried several other PWB-L chain batches – same problem. Tried all other available 10mm Lewmar gypsies for the windlass -- revealing there is no Lewmar gypsy that will fit that chain. Need to either replace the windlass or the chain.
Sold the almost new anchor chain on TradeMe auction website in October 2007 for half what we paid for 10 months earlier. Ouch. Lucky sod.
Tested new Italian-made Maggi grade 40 anchor chain with Lewmar 002 gypsy, independently break-tested confirming Grade M/4/40, acquired, marked, delivered and installed by Grant McDuff of Chains, Ropes, and Anchors. (second iteration in October 2007).
New Lewmar 002 gypsy matched to Maggie chain swapped gratis by Kiwi Yachting (because we'd just purchased a new 003 that wouldn't work). Thanks Blair!
Acquired new Lewmar wired windlass remote from Kiwi Yachting and installed to replace the old one that failed.
Re-galvanized 60lb CQR Anchor and replaced lead when at Orams Marine (while in the yard for 2007 exterior and rudder work).

Entertainment system replacement

Replaced old 1998 Sony 13" TV/VCR combo with new solution.
Acquired and install new 17" SONY LCD, Mac Mini DVD player/EyeTV tuner/recorder and 500 GB iTunes music, photo/video server solution (and powered Cambridge Soundworks 12V speakers & sub).
Acquired and programmed Harmony 550 universal remote to replace 5 remote controls.

Recreation & toys

Acquired an inflatable kayak and two collapsible paddles
Acquired two new dive tanks, masks, fins, snorkels and get regulators serviced, hydrostat and visual tests on old tanks. Figured out a place to stow the extra gear.
Replaced cockpit dodger hatch cover.
Acquired new custom fitted bed sheets and mattress pads
Acquired new pillows.
Received quotes for various bimini and cockpit shade alternatives. Decided not to do, then changed our minds in November 2007 and decided to proceed with one option. No vendors available at any price until Feb 2008. Now may not get done.

General maintenance and interior work

Varnished mahogany hatch rings with satin varnish.
Annual spring cleaning: after every winter living aboard in Auckland, we have significant work to do to clean all mold and mildew out of every nook and cranny on Whisper. It takes several days, it's a dirty toxic job, but you can eat out of her clean, dry bilges when we are finished.
In late 2006, we had Whisper's carpets and all upholstery professionally steam-cleaned. We clean her portlight curtains once or twice a year to keep them mildew-free.
DIY (with help) annual cleaning and waxing. Until this last serious and professional cut and polish done by Orams Marine, Robin and Duncan, along with university Students Chris and Tristan / Sam, and they would engage in a one or two weekend marathon exterior cleaning, polishing, stainless maintenance, rust removal, and hand-waxing of Whisper.
Bottom cleaning and zinc replacement. Every eight to twelve weeks, Andy Murdoch form Marine Clean LTD came by to clean Whisper's hull. Water temps are < 60 degrees Fahrenheit most of the year, so in my opinion, he earned his $125 per cleaning.