Set it all up, then switch off.

It's been in planning a while, and a lot of things had to be organized for the solar panels to be mounted. I started with a simple radar and antenna pole which came with the boat.


I needed plenty of solar power so the pole had to go. Two large panels were to be sited at the aft of the boat. But the radar had to get in as well, plus the antennae, and I wanted a solution which didn't obstruct a wind vane and hold a dinghy in davits.

So I got a welder to draw me a design, and then I changed it because it became hugely expensive, and then I had to wait for hours for them to show up and actually work on it.
This is the basic shape, with a detail of the new wiring:

And after we mounted the panels, the radar, the antennas and the davits it sort of looked like this:



From the top, you can see the solar panel surface is quite huge:



Next up were three service batteries to replace the existing two. We now have 300 Ah in battery power and 270 Wp in solar power. I've got an emergency 1100 Watts back-up generator and the new alternator regulator, so it's hard to imagine us ever being out of power.

And we'll need it to power all our gizmos such as two portable PC's, satellite phone, instuments and lights, fridge and chart plotter. I've spent the day yesterday setting up the main navigation portable with maps and software. It'll take some tweaking and tuning to get it all up and running. I hope I can get away from it all once it's set up.

That'll be the real challenge of this trip: switching everything off every now and then and enjoy the places we visit.

Look outside

Another week end, another step. Every week end sees us advancing slowly but this Sunday I added a portlight to the walk through from the saloon to the aft cabin. To ensure ventilation, one hatch is a bit meager so a new portlight was the answer.

First I took very accurate measurements, as cutting large holes in the outside of a boat is never done without precautions.



After drilling a pilot hole and double checking its position, I cut a large hole with a circular saw.



Next was the masking of the area around the portlight for excess mastic. I always take good care in this stage, as a well masked area makes the job so much easier.



The fitting of the portlight was quite easy, and now we have some natural light in the walk through as well as better ventilation in the aft cabin. An added benefit is a way of talking from the chart table to the steering position. Sound transmission was always much better from the outside, I hope it is now possible to hear someone on the inside.

After cutting the inside frame with scissors, the finish looks quite professional.



I also started wiring the solar panel array, and I hope to have this finished by next Friday with some pictures.

Prep work

We had some fine weather this week-end, so we got to do some work on the outside. It wasn't very hot but there was some sun instead of the usual rain, sleet and snow we've been having the last months.

So on Saturday, we went out and measured the exact location of the wind vane supports. It took some doing and re-doing as both inside and out there were some obstacles. But finally, we got it right as you can see in this picture:



Next were the backing plates. After drilling pilot holes, on the inside one location out of three had landed where a reinforcement was already in place. So two more reinforcements were needed. I put those in place on Sunday, while Ingrid was cleaning fenders and taking off the last layers of varnish from the hand-holds. There are now no more varnished surfaces outside, apart from the companionway. We like the natural teak look better and it doesn't flake as quickly.

After I epoxied the pieces in place, I added a few layers of fiber cloth and epoxy for an even load distribution. Hopfully, next week work will start on the arch, so I can start finishing the vane construction soon.

All engine systems go!

I felt an absolute grease monkey this week-end. I spent a lot of time doubled up and lying face forward through the starboard engine hatch, squeezed through the hatch with both arms.

The positive news is, the engine is now running again, with a new raw water pump and a new alternator regulator and new brushes. On the minus side, I'm still a bit stiff from laying in the lazarette with my legs bent back over my head.

I first replaced the old raw water pump with a new one. I was never too happy with the pump as it required constant attention, adjustment, grease and it still dripped salt water from time to time. So I enquired into replacements and learned that a new, identical pump was hugely expensive and I'd still have an old design.

the old pump aka "grease guzzler"

So I tried to find alternatives and the people at ASAP got me a Johnson pump which required minimal adjustments. The new pump did have slightly different measurements, mostly to do with the entry and exit being 3/4 inch instead of 1/2 inch. So I got some basic connections from my local plumbing supplier. I had the pulley machined to a slightly larger bore (1 mm extra) and I now have a brand new, non leaking pump.


Once this was finished, the engine would run so I could continue work on the engine alternator.

I had ordered the Sterling advanced alternator regulator as I had experienced I never got the service batteries quite to 100% full. The shore power charger is a 10A DIY jobbie which is good at topping up, but it never really bulk charges or deliver the final charge modern chargers can. A new shore charger is on the wish list, but not that high as we'll be spending a year away from marinas, so shore power availability will be limited.

The engine alternator is 35 Amps, and as long as we motor for several hours and the battery state is not too badly discharged, it has the capacity to keep the batteries topped up. But the in-built regulator is a simple device, and as the batteries got older, charging them got more difficult and lengthy, even when motoring for longer spells.

I would have preferred a heavier alternator, but that would have meant a different pulley set-up. And I just bought 270 Watts in solar panels, so any alternator power would be an extra. The main thing is getting the batteries charged as rapidly as possible with the existing one. So I got the regulator as it promises to use all 35 Amps in bulk setting.

I installed the regulator, which meant disconnecting the alternator twice while doing checks and adjustments between them.
After taking the alternator out, I checked for wear and found a brush needed replacement. It took an alternator builder two weeks to get the Lucas brushes from Italy. I then connected check wires to the brushes. They are the yellow wires in the picture.


I could determine that the alternator has - as I suspected - negative coil field control. This is important to adjust the settings of the regulator.

I took the alternator out after running the engine and connected the wires as described in the Sterling manual. It's pretty clear from the little booklet how to do this, but the warnings are sometimes a bit dramatic for a technically challenged mechanic such as myself.

I tend to think for long periods, all the while staring at whatever device I'm tinkering with, hoping there isn't anything I've mysteriously overlooked. In the case of the water pump, this was a good thing. I almost forgot to tighten two hose clamps on the exit side of the pump, which would have given a nice anti freeze solution shower. Thinking long and hard while looking at the pump made me hand check all clamps, just before trying the engine.

In the case of the regulator, the warnings made me re-check everything I did, even though I got it right from the start. But after spending hours in the cramped lazarette, I finally started the engine, and behold! It worked perfectly.



The lazarette isn't actually that cramped as lazarettes go, but laying flat on your belly in one isn't the way they're meant to be employed. It might serve as a nice pilot berth, but I think I'll stow it with all the extra gear we'll have along. It'll do perfectly and I won't have to lay in it anymore. I'll use the soft bed in the aft cabin. I think I'll buy a new mattress to make it even more comfortable. And a large fan for those hot evenings in the Caribbean.

Almost set to go!

I've got two rather large solar panels sitting in the main cabin. They're waiting for someone I'll be having over to take the measurements for the arch. A big step towards power independence and, in fact, the only item needed before the departure.

At the same time, I got most of the large scale charts I need for the different crossings. The small scale charts and pilots will be bought later, but the planning phase is now well and truly underway and advancing rapidly.

I have most of the engine modifications set up and next week-end, some time will be spent putting all these in place. I made a second engine hatch last week so I can now get at the engine form both sides.

The new hatch is in the cockpit locker and is sited above the oil filter. This was previously very difficult to reach, so a big advance there.

At our annual flea market, I got two diesel jerry cans for € 2 each, so now I can carry a total of 280 litres of fuel. This should do for the trip we intend to make. I'm still looking for some second hand diving equipment and a second hand inflatable dinghy. The spending doesn't end there, as a Navtex and sattelite phone are also on my wish list. But as far as hardware goes, we're almost set to go. Now only for winter to end...

I've got the power

This week, we got one of the most important purchases sorted. For a year at sea, solar power was a number one priority. I managed to buy two 135 Watt panels for under a thousand Euros. Once the panels have arrived - this should be in the next two weeks - we can proceed with the aft structure to support these.

The panels are Kyocera and should be able to fit next to each other, creating a 3 m by 70 cm solar array. This will deliver all the necessary power to use the instruments, fridge and lights.


After another cold spell which put a lot of the smaller jobs on hold, this weekend will see some work finally getting done. I did get a chance to try the new spray hood on, and only one part of the zip now separates us from a new and improved tent protection.

Meanwhile it was my birthday and I hope some money will be going into the mainsail-fund.

The need for speed

All is now ready for the cold of winter. I was a bit too optimistic taking the alternator out. I thought it would only be a week or two before I got a new one in. But things are always more complex than you can imagine.

So in the end, I won't be buying a new alternator as this would introduce a point of failure into the system. The engine is only designed for a 40 Amp alternator and I already have a 35 Amp one. So putting in a heavier one would put a lot of strain on the belt. And since I can't easily set up a two belt system, I will now put in a smart alternator regulator. This will charge the batteries much faster. This is very necessary since the alternator with the normal regulator charges quite slowly.

And since I've decided to put in an extra service battery, I might need the faster charging sooner rather than later. This will bring the total to 360 Ah service and 105 Ah start battery. With 350 Watts of solar power, the electric system should hold out under normal running load with the fridge on.

So now the cabling is in place, only the new battery box has to be installed next to the diesel tank. I'll have to put in some safety so any problem with the starter battery doesn't affect the tank.

Next item is wind propulsion. I'm having UV strips on the genoa upgraded. Next on the list is the main sail, where a new one will have to be made. I'm still not sure what to do with the Genoa 3, perhaps it'll go on the cutter stay but then I will lose the ability to furl that one. It has served well as a heavy weather sail- up to F8. But perhaps I'll need a high aspect jib as a replacement.

So much to decide, and the sprayhood is in the process of renewal as well. Once all sails and engine are ready, it's only additions I'll be needing. The arch for the solar panels will get welded, and the list right now gets shorter in a faster rate than new items are added.

So that's good. Six months to go, and we're still on schedule. Once everybody is at it on sails, sprayhood and arch, it's time for some R&R, two weeks of skiing in France. It'll be well deserved.