Boat Projects Completed

 

Exterior New fuel tank fuel gauge All new rigging wire (upsized to ¼” on mizzen) with swage fittings aloft & Sta- Loks at  deck level (except headstay – re-used existing Norseman fittings) Converted split backstay to double backstays, one with SSB insulators New lifelines Masthead tri-color / anchor light, LED Red (75% cuprous oxide) Pettit Trinidad antifouling paint Wind scoop Spare fuel jugs Hurricane lamp & mineral spirits 66 lb Manta claw anchor, 50’ 3/8" G4 galvanized chain, 200' 5/8" 3-strand nylon rode Mooring shock absorbers Install Furuno radar EPIRB Removed old spinnaker pole deck mounts Moved Danforth anchor bracket and anchor from bow to stern pushpit Removed stern light bracket Repositioned primary winches further aft Removed cleat on starboard cockpit coaming Serviced (disassembled, cleaned and lubricated) both primary winches Removed, cleaned and lubricated secondary winches Shaved hatch boards to relieve jamming Patched inflatable dinghy Replaced spark plugs in outboard Installed fuel filter in outboard Inspected and re-folded all sails Serviced mainsail halyard winch Designed / fabricated sheet guard for diesel heater chimney Washed all dirty lines Removed old name letters from transom with heat gun & cleaned left over glue Freed up the stern ladder stand-offs using PB Blaster, installed rubber tips Measured lifelines for replacement order Replaced outboard motor throttle cables Rebuilt outboard motor carburetor Repaired mid-ship companionway sliders Rebuilt holding tank manual overboard pump Designed and fabricated new handle for moveable hand pump Re-bed miscl. holes near dodger and cockpit Serviced 2 more winches Washed, folded and stowed dinghy Loosened rigging and had both masts un-stepped by crane Assembled old wind generator to sell Removed starboard dorade box and silicone’d under there Removed rigging from un-stepped main and mizzen masts and measured for replacements Removed all old lights and fixtures from both masts Removed/sold TV antenna & mounting bracket Removed propeller & pulled prop shaft Cut & beat out the old cutlass bearing Scrubbed & waxed topsides Removed most thru-hulls and super-serviced all of them Cut the number of thru-hulls in boat by half & hired Jerry Evans to seal old holes with layered fiberglass Cleaned, sanded, taped and painted cove stripes and boot stripes Cleaned and sanded the prop shaft Put prop shaft back in Painted interior of thru-hull fiberglass patches that Jerry installed Drilled and epoxy-coated hole in rudder for emergency steering lines Jacked up the davits for the welder to beef up davit arms with flatbar braces Removed, cleaned and silicone'd chainplate covers Repaired autopilot plug Rocky applied new name decals on the transom Waxed the transom and the new name Pulled old electrical wires from both masts and ran messengers Cleaned the VHF antenna connector Installed / re-installed freshly serviced thru-hulls Installed heavy duty anchoring U-bolt in stemhead, w/massive ss backing plate Disassembled Harken roller furler drum Tapered old headstay for installation of new headstay Wet-sanded boat bottom with coarse (black) 3M scrubbers Sanded and painted Jerry’s newly gel-coated patches - Ground back around strut base checking for bolts Repaired water-soaked hull spots: ground out, dried & rebuild fiberglass  Repacked rudderpost stuffing box Installed the new headstay in Harken extrusions & re-assembled Mounted new stern light bracket on mizzen masthead Mounted new tricolor bracket on main masthead Attached eye straps to main spreaders for flag halyards & lazy jack lines Filled various mast holes with JB Weld Installed new spreader lights, one swivel mount & one fixed New spreader boots Riveted radar mount to mainmast Bolted custom wind generator mount on mizzen mast Installed new cutlass bearing Had propeller re-pitched & reconditioned, and reinstalled it on the shaft Installed new shaft zinc Installed raw water intake strainers (engine and sea chest intakes) Designed/fabricated/installed removable air conditioner box over main salon Cleaned & oiled teak in cockpit area Designed/fabricated pedestal gearshift upgrade Completely rewired both masts, bundling wires in foam rubber tubes Canvas: Cockpit cushions of closed cell foam & Sunbrella: (5) hatch screens, (3) lee cloths.  Sunbrella covers for primary sheet winches, GPS, compass, scanner screen Large main boom Sunbrella awning/rain catcher Enlarge hole in mainmast for radome cable: 1-5/8” x 5/8” Enlarge hole in mizzen mast for 10g wind gen cable: 1-1/8” x ½” Bond new seacock (clean other bonds) Mount: 2nd spreader light, steaming and stern lights Pre-wire steaming light & mizzen stern light w/ disconnect fittings Attach 12g wire split to 10g spreader lights wire Strip shield off 6g wire 6” above mizzen mast base Cut new halyards Install new mizzen mast electrical wires Deck plate over old hole in aft coaming Design/fabricate PVC hawse pipe for stern anchor Wire Air-X wind generator, Remove and lube masthead sheaves Connect all main mast electric wires Battery-test all mast lights while masts are still down Epoxy-coat step area inside mainmast's base Ospho, prime & paint mainmast step in bilge Install all new main and mizzen mast stays, shrouds & halyards Fabricated necessary tangs, toggles & link plates Design/fabricate/install custom, heavy-duty backstay fittings Re-install mizzen step plate Re-step both masts Install booms, etc New winch handle holster Installed flag halyard & lazy jack shroud cleats Shorten headstay & re-install Adjust/set all spreader angles Mount RadioLabs wi-fi antenna on shroud Install new opening portholes in shower & aft cabin Fix leaks in holding tank discharge pump Nicopress new main & mizzen topping lifts Bed fuel fill deck fitting cap rail area Masthead: triadic Re-fill compass fluid Install main-masthead windex Clean mizzen sheet and running backstay lines Seize on new davit lines Splice on new main sheet traveler lines Install rigging toggle extensions on main shrounds, etc Tighten roller forestay Seize eye/thimble in genoa halyard Seize eye/snap shackle in mizzen halyard Bend on sails Wash running backstays & mizzen sheet Sailmaker: Sunbrella covers on both genoas, re-furbish mainsail, replace broken track car on mizzen. Also repaired kayak seat straps Made up custom lazy jacks Extended upper tang plates for backstays Clean up starboard cockpit locker, including wiring runs Clean/paint small mushroom anchor Barbara: mainsail & mizzen sail covers Installed awning backhaul block on mizzen mast Build workbench for new slip on the main pier Sand & resin-coat Loran antenna Clamp & seize all spreaders Raise wi-fi antenna Remove/stow air conditioner & boom awning for the winder Fabricate spray dodger hardtop Paint anchor marker buoy Extend pedestal throttle handle linkage Build dock box as per new marina regulation Design/measure for mast pulpits New plywood lazarette forward bulkhead Rebuild fuel gauge viewing port Clean, Ospho & paint fuel tank top, mostly on starboard side Replace/re-bed fuel gauge viewing portlight Design/fabricate bimini framework ! Design/order mast pulpits Clean/refurbish Dickinson BBQ Remove/paint/sell old manual windlass Install bow pulpit port/std running light Re-bed bow pulpit mount Wire fish zinc to mizzen shroud Replace O-ring in heater’s diesel deck fill Streamline air conditioning installation Chain Locker / Foredeck / Electric Windlass / Deck Washdown Materials & Tools: ¼” aluminum plate x 38” x 18” 3/8” high grade (untreated) exterior plywood, 24” x 32” Deck access plate, up to 12” OD 10 cc measuring syringes from pharmacy (MEK will erase lines; mark w/tape!) Plank for running light Fiberglass roller (“bubble buster”)  (6) 1½”  ss countersink bolts, ¼ x 20 (2) ½” planks for divider: 38” x 16” and 26” x 16” ¼” high grade (untreated) exterior plywood, 24” x 32” for deck core 40’ ¾” high-pressure water for washdown pump ¾” 40-50-mesh raw water strainer ¾”-to-garden-hose thru-deck fitting for washdown pump 1¼”-thick teak mounting pad, 12” x 9” (salvage from old windlass’ block) 1 can of 407 thickener Gel coat touchup kit KiwiGrip deck paint 2nd anchor chain deck pipe 7/16” galvanized shackle for claw anchor Job Steps: Remove/paint/sell manual windlass: Remove chain/rode from chain locker & store Set new windlass up on deck for pondering. Check manual for shaft length, etc, etc. Cut out old mounting block with sawzall (tie up so it won’t crash down into locker!) Remove vent cowl vent & base Trim vent tube under cowl vent Drill pulpit & cap rail and run wire for new fwd running light Connect running light wires Pull old running lights & seal holes from inside with ‘glass backing pad Epoxy-seal all exposed deck edges & old drill holes Divide chain locker using several removable planks held in place with side blocks Install PVC wire & water hose conduits into chain locker Install wire running boards in upper chain locker Install washdown pump & wiring Install windlass control box & wiring Run wires for windlass, from battery to motor location. Plug upper locker overboard drain hole & drill drain hole down into chain locker Check angle of windlass so 2nd anchor chain clears deck pipe as it leads to the gypsy Seal all raw wood shelf edges w/resin Epoxy-seal edges of upper shelf drain hole Install washdown deck fitting Washdown pump plumbing Cut mahogany slab for windlass mounting pad Cut back deck lip only where aluminum plate will be (18” section, both sides) Sand/clean underside of deck for aluminum plank Plug chain locker bottom drain hole Epoxy/glass bottom of chain locker for perfect drainage Drill port/starboard drain holes Glass-over / fill-in old cowl vent hole & water deck fill hole Grind remaining lip corners to bare glass Grind out 2” from edge all around using 24-grit disc, but beveled gradually up to existing deck level Seal exposed balsa core with epoxy Cut/fit/bend aluminum plate Camber aluminum plate (run over it with the truck!) Rough up upward side of plate Drill bolt holes in plate Secure (tie-wrap) deckwash pump hose under V-berth edge Run deckwash pump hose thru PVC guard pipe and thru the bilge to the seachest Install windlass breaker switch Seal upper corners of main bulkhead against water intrusion Cut 3/16” plywood to fit over entire hole Clamp plywood to plate’s camber & ‘glass to hold it Pre-drill oversize bolt holes in deck and fill with epoxy Clean/acetone underside of deck for aluminum plate Epoxy & bolt aluminum plate up under deck with resin thickened with 404 (thru-bolt with countersunk bolts) Epoxy-tab PVC water hose shield under V-berth Wrench-tighten plate thru-bolts when epoxy has set Trim plywood filler piece edges back ¼” all around for goop Bevel bottom edge slightly for curve of lip Plywood filler piece fiberglass lay-up schedule: - Bottom of plywood: 1 layer mat + 2nd layer mat on sections beyond aluminum plate - Top of plywood: mat, mat, roving, mat, roving, mat, mat (7 layers = ¼”) (leave 2” all around edges for final taping to deck, only 1 layer mat to the edge) Final acetone wipe-down Coat aluminum surface & lip with 404-thickened resin and set panel in place w/ weights Goop over (seal) countersink bolt heads Run fan when grinding fiberglass, and put on baby powder beforehand! Mark deck all around to show where windlass will finally mount when deck is sealed! Glass all around panel with 4 strips of mat, feathering out on main deck bevel Final panel build-up: mat, roving, mat, mat Finish & pre-drill mounting pad for windlass Coat mounting pad’s chain deck pipe wall with 404-thickened epoxy Over-drill mounting pad bolt & sensor holes, fill with epoxy, and re-drill Final foredeck fairings with resin thickened with WS 407, using fairing stick & long 2x4 sanding block Last foredeck patch overcoat with clear epoxy Scuff-sand and paint foredeck patch with 2 coats white enamel paint Sand & re-drill bolt & sensor holes of windlass mounting pad, try on for size Epoxy coat windlass mounting pad Run deckwash pump power (red) wire to nav station panel Grind away old non-skid around all new holes Drill/cut all windlass thru-deck holes & epoxy inside edges - Mount windlass 2 ½” to port of centerline & 28” back from the forward non-skid line - Drive shaft is only 1¼” – needs 1½” hole Sand & paint windlass mounting pad (over the epoxy), 2 coats min. on sides Bed windlass mounting pad with Rope Caulk & mount windlass Install windlass foot switches, etc. Attach motor, hook up wires, etc Final trim/fit divider boards Cut hole & install second anchor deck pipe Rope-to-chain splices on both anchor rodes Install 2nd anchor rode & chain & shackle to claw anchor Install deck cleat to port of windlass for port anchor chain Put stoppers on anchor rode bitter ends in chain locker, port & starboard Make/mount running light mounting plank & bracket (with 8° downward tilt to compensate for pulpit’s upswept angle) Move main sheet winch & cleats Trim dodger bolts Mount cross plank & nav light on pulpit Mount BBQ on new bracket Chafe straps on forward deck awning ties Mount mast pulpits Build Clearwire modem/antenna “birdhouse” & temp mount on mainmast Fit battens to dodger windshield Snaps (bedded) on windlass base for Sunbrella cover Replace starboard car-track cleat bolts Replace missing wood plugs in cap rail Dry out & seal port spreader light Replace/re-mount cockpit speakers Canvas    Re-attach port pull strap    Bimini top    Dodger/bimini connector piece            w/windows    Dodger batten sleeves    Bimini tent fly Renee – strip/sand/clean/oil exterior teak, 55.5 hours Tape off foredeck for non-skid painting KiwiGrip paint foredeck Put sealer into inflatable dinghy Glue dodger trim at entry Superglue dinghy valve casing New mainmast boot ScotchGuard forepeak slip covers Pull/clean forward hatch Nicro vent Replace old 3” Nicro solar vent over galley with new 4” unit Bed leading edge of dodger hardtop Assemble wind generator & mount on mizzen mast Connect all Air-X wiring Tape over exposed wires at back of running lights and wind generator Wash/flush/test both Sun Showers Install dodger battens   Renee - Compound/wax all smooth gelcoat surfaces -  cockpit, deck & coachhouse = 17 hrs. Put up lazy jacks Aim port spreader light forward Replace 4 spreader tie-wraps w/new black Remove windlass gypsy guide arm Cut out access hole at stem head to get at anchor roller bolts Relocate deck washdown fitting starboard Remove anchor rollers. Repair wood underneath starboard anchor roller, replace some of the long wood screws with short ones for bit bolt washers. Remount anchor rollers angled slightly outboard to align with windlass Switch 150’ NACM chain for 150’ ISO Long rope/chain splice to new chain Replace leaky dinghy valve Check out / fire up outboard motor Replace broken wind generator blades Lash fuel jugs on port/starboard rails Clean outboard carburetor & spark plugs Taped & re-stitched torn genoa with Wayne (10 hours) Hose-blast holding tank vent lines Wayne: Sun shade panel Open/unclog all scupper hoses, bilge pump hose & head sink drain Remove frozen (former) genoa halyard mast cleat Cut/install a deck plate over stem head hole Cut/install a deck plate over afterdeck hole Adjust (tighten) bimini top Haul-Out Make bucket porta-potty Wash hull with Sno-Bol Outboard motor – fix tilt! Pack dinghy to exchange Check/mark helm center spoke Record whether prop shaft is offset for pulling past skeg & rudder & which side Install new thru-hull for toilet direct overboard discharge & connect plumbing Fill in old running lights socket holes Fill in erroneous anchor locker drain hole with epoxy, port side forward Clamshell covers for chain locker drain port/starboard holes Bill - Water-blast bottom Clean prop shaft & strut Scrape all loose paint off with putty knife Open the few water blisters on forward port waterline Sand bottom & fair where paint flaked off Tape off & sand down old boot stripe Send in prop for 11” pitch Rough up smooth bottom surfaces with 40-grit Open & acetone-dry little blisters on forward port waterline Epoxy-fill little blisters on forward port waterline Remount propeller, paint it and shaft with West epoxy Install (2) new shaft zincs and stow (4) spares Light-sand epoxy on prop & shaft, then one coat Trinidad bottom paint Primer coat on old, sealed running light sockets Mount genoa halyard wire winch Make/install cover plate for stem coaming access hole Paint over old running light sockets & touch-up cove stripe Install garboard drain plug in the bilge sump, epoxy-line the hole inside, epoxy over flange outside Morgan - compound/buff & wax hull Wayne/Jim – make davit lifting strap for inflatable dink’s forward end Cut & hinge old swim ladder Cover garboard drain plughole with a wasp screen Cover all deck scuppers with screens Make/install PVC scoop/cover for holding tank vent lines Windvane: Mount windvane rudder Hang new inflatable in davits Shorten mizzen topping lift wire Set mizzen boom onto bimini frame for airvane clearance measuring purposes Wet-sand windvane rudder & trim tab from waterline down, 60-grit Cut & shape airvane mounting plank to fit new, welded railing plate Epoxy & paint cut edge of mounting plate Cut airvane mast down to 25” Harry:  - Shift davits lift points 6” higher and 6” farther aft - Airvane mount platform, 6” (available!) x 12” x ¼” ss plate welded to bottom edge of stern rail tube (with strut vertical down to deck/coaming ??) - Swim Ladder: weld on all 4 fittings, seal all tube ends, add stop bar across so flip-down stops short and angles outward slightly Thru-bolt airvane ss plate strut’s base plate Drill (over-drill, fill & re-drill) airvane mounting platform to match mounting plate Re-paint airvane mounting platform Charlie: Fill in/gelcoat old swim ladder holes Re-mount swim ladder to port Install airvane assembly & hook up to rudder trimtab Cut/file airvane mount bolt ends Make backing plates for Coat’s grab rails Mount 2 grab-holds/steps above swim ladder to complete the boarding set up Trim off bolt ends inside lazarette Make 8” x 32” fuel jug platforms for rails, ¾” port, 3/8” starboard Provisions Cole - Paint outboard motor cover dark green Renee – Paint dinghy white Orange paint highlights & RI reg. numbers on dinghy Photo finished drain plug Bottom Paint - Paint prop & shaft with West epoxy, then Petit Trinidad antifouling - Tape, sand & wipe down old boot stripe top line - Re-paint boot stripe using primer first, but a thinner line, i.e., raise the waterline 1” - Wipe down windvane rudder/trip-tab with acetone, then 1st coat Petit Trinidad - Petit Trinidad on all bare spots - Rinse bottom, wash keel below galley sink drain! - Do first coat - Add tetracycline only to last 2 coats of bottom paint - Insert garboard drain plug w/Loctite, a big wrench & bottom paint over it - Move all jack stands & sand/paint those spots Final tap & tighten shaft zincs Make/stow 2”x 6”x 6’ fender board Support boards for fuel jugs on cap rails Decals on outboard Pre-Launch Dinghy floorboards – epoxy edges to seal & prime, paint white Top off propane tanks Top off fuel jugs, including gasoline Move dock box stuff aboard Get the vice & owl off the workbench. Paint underside of keel Install masthead tri-color Wayne - weather cloth, reversible Move Autohelm 3000 motor aft ¼ to 5/16” Re-mount shroud cleats Plug bike tubes Make up lock cables for dinghy & outboard Final outboard motor repairs Fix leak in deckwash pump Shift wi-fi antenna inside shroud & tape top Shackle an anchor chain pennant line onto stem eyebolt for that purpose Replace steering wheel shaft retainer spring clip with slightly larger size Final outboard motor repairs Spray graphite on mainsail mast track Anti-fouling paint on inflatable dinghy Canvas Shop: - Replace broken snaps on cockpit shade panel and filler piece - Patch/protect chafed areas along after edge of boom awning and forward end of mainsail cover Remove/re-bed/remount forward starboard boarding gate stanchion Staysail stay and halyard rig Service & mount staysail halyard winch Mount staysail sheet cleats on port & starboard cockpit combings Cover cockpit console tabletop with non-skid epoxy-coated panel Replace/relocate port cockpit combing genoa roller furling pennant cleat Mounted staysail sheet block pad eyes & blocks Mounted life raft cradle & life raft Rig mainsail deep reef lines Rig mizzen preventer Install staysail running backstays Install CPT autopilot (remove old Autohelm 3000) Set up windvane tiller pilot Canvas Shop: - Re-stitch & small-patch entire bimini - Replace broken snaps as needed Rebuilt busted whisker pole Life Raft/Abandon Kit in cockpit locker Final-tune rigging Cotter-pin & tape turnbuckles (incl. triadic) Raise radar reflector Set up jack lines Check all scupper thru-hulls for leaks at the elbows when heeled over. Rig main boom preventer Replace broken wind generator blades Patch mainsail (Davina) Remove tape from forward vent (Davina) Longer reef points on mainsail (Davina) Re-bolt Harken base fitting Nicro-press Shaft-Lok cable Freshwater rinse bimini & connector windows, all deck ss Wash decks & cockpit New CPT belt Machine shop: drill new CPT wheel pulley Clamp/cut/finish tiller pilot / windvane cables Turks head on steering wheel mid-point Re-run main topping lift thru block & forward along boom. Shackle hard-wire topping lift to boom end Patch leak in red kayak tube & re-pack Cut/whip deck securing lines for windvane rudder Re-secure Auto-Helm cable clip at trim tab wing using lock nuts Grease Harken bearings (Stopped recording repairs for a while) Wire-wrap split sections of Auto-Helm steering cables Set up telescoping whisker pole on mast Rebuilt broken Air-X wind generator Bought SCUBA tank, regulator, BC, etc Scuba tank tested & re-certified Patches on deck awning Remove / re-secure loose Air-X blade; remount Install new wifi antenna & router Re-stitch mainsail cover zipper & patch lazy jack chafe New port zipper on dodger center window Re-bed inboard forward life raft mount Re-bed/repair coachhouse (aft) brow strips Siphon diesel from all 4 yellow jugs Make/mount new rail boards for fuel jugs Dinghy: - Clean on beach - Replace drain valve & oarlocks - transom yoke to hoist w/ob on it - towing yoke - Re-secure forward hoist strap Replace shaft zincs / clean bottom Patch torn mainsail near reef clew cringle Replace broken mainsail mast track & boom track slide cars Patch center bimini top chafe from mizzen boom Tighten CPT Autopilot belt Canvas Shop: - Repair torn deck awning - Repair torn dinghy lift strap Replace missing windvane trimtab yoke bolts New mizzen running backstay lines Remove SGC-230 New cap nut on foredeck hawse pipe & Ospho foredeck Re-run anchor chain snubber for quick release Mark primary anchor chain lengths with colored tie-wraps Wilson: scrub & oil exterior teak 9/30/10 Clean/repaint dinghy bottom w/Petit 1841 Remove genoa for repair Clean/whip genoa sheet ends Replace outboard motor impeller (Sunny) Touch-up boot stripe, port forward Lobo sailmaker: Re-build genoa leech/sun cover Re-stitch genoa luff boltrope at head *Get Sunbrella back from him! Marina: Wash/wax hull topsides & decks Clean bottom before leaving marina Dump water out of port dinghy pontoon Maria (Rana Azul) re-stitch torn awning Replace rusted clip ring on steering wheel, then cover with grease and protection. Erika/Lobo Canvas: Re-stitch big awning with UV thread. Move rain-catcher connects aft Replace Auto-Helm windvane’s rudder post bearings Remove old prop shaft zincs. Install one new zinc Fix stern running light on mizzenmast Spray graphite mizzen & mainmast tracks Remove/re-mount (thru-bolt) broken galley faucet Replace lost mizzen sail's lower batten GCSM Boat Yard Work List – Spring 2011 At Mooring: Top off fuel tank Remove/seal coachhouse brow Rinse/dry/remove/fold/stow sails & dodger All Sunbrella in for re-stitching Covers on winches & compass Dry-dock: Remove Auto-Helm airvane Inflatable – clean/roll/store Remove/clean/stow CPT autopilot Remove/stow all deck gear Clean/Ospho/grease dinghy locks Top off fuel tank Seal forward hatch top Secure board or whatever as rain visor over head porthole (to leave it open) Rinse/dry/remove/fold/stow bimini, awning Mainsail & genoa in for repair (Irish SM) Strip bottom (incl. rudder post boot) (Dave) Wash/compound hull (Morgan) Renee: Clean windvane rust stains Clean prop shaft & strut Clean all fenders Wax hull Cole: Outboard motor – flush/new wires/new plugs/spray for storage Service Honda generator Leaving: Rinse/dry/remove/fold/stow bimini, awning, etc Stow life raft belowdecks Lock cockpit locker hatches Boat Yard Work List – Fall 2011 Post signs around yard for another 425 lbs of chain/anchors to be re-galvanized Recondition/polish prop Check shaft on lathe & clean Re-galvanize chain & CQR Bend on canvas (bimini, etc.) Install new cutlass bearing Remove/clean thru-hull bronze cover fittings, clean out thru-hull entries Epoxy-fill thru-hull bronze cover fittings screw holes for re-drilling Clean/sand bottom fittings, etc & tape off in prep for barrier coat Install shaft & zincs Rinse Manta anchor chain Paint all underwater bronze with zinc Bottom Prep: Sand off zinc overspray Tape over zinc-coated bronze Leave garboard drain plug clear for epoxy Get replacement stainless steel garboard drain plug & use lanolin for installing Find/re-bed port salon leak (starboard upper chain plate deck plate) Pre-stir bottom paint & assemble bottom-painting materials Dorothy Canvas: +1-904-304-8523 - Final re-stitching on bimini - Fix horseshoe strap - Replace broken snap on dodger & re-stitch entire - Sunbrella slip covers for settees - Re-stitch Dodger Again! Bottom Dave: Fair waterline for 12” Fill blisters (& roughest bare spots) Wash bottom, wash keel below galley sink drain! Epoxy bottom First coat anti-fouling paint Total Bottom Paint: 5 gal = 2-2/3 (2-4) coats Sand keel bottom, then anti-foul: 1st coat: windvane rudder, inside t-hulls, engine & seawater manifold intake t-hull screens 1st coat: between main rudder & skeg, keel bottom; 2nd coat overall 3rd coat: waterline, forward edge of keel & windvane rudder Peel all blue tape Re-mount engine & seawater manifold intake t-hull screens Move all jack stands & Dave will sand/epoxy those spots Anti-foul jack stand spots, 2 coats Patch inflatable on dinghy floor below/aft of port oarlock, re-do old patch Replace both anchor rollers Green paint: - Tape, sand & wipe down cove & boot stripe top line - Re-paint boot stripe using primer first - raise waterline 2” Patch ‘glass & gel coat on lower stem (Charlie) Plug cap rail screw holes at fuel jug stations Re-bed porthole over bunk Trim/sand new cap rail wood plugs Re-paint inflatable dinghy, MOB horseshoe & Life-sling pack Solar Panel mounting bar, brackets & davit mounts (Coats machine shop) Remove port davit & drill solar panel wire entry/exit holes Paint dinghy numbers in orange Pre-wire & re-mount port davit Hang solar panel Test-run outboard motor Clean generator carburetor & test-run Paint dinghy floorboards (2 coats primer + 2 coats Rustoleum Marine w/UV) Clean/oil deck teak Install bearing sleeve in top of windvane rudder shaft New shackle for Manta anchor Assemble dinghy, incl. oars Re-install repaired windvane rudder post Return JB’s scaffolds & plank Wash decks & cockpit; Wax smooth gel coat areas – Renee Set up dock lines & fenders Label all fenders with “Silverheels” Cut/fit fender covers Top off water tanks/jugs Mainsail & genoa from Irish Sail Lady (Linda) Stow main boom deck awning Paint underside of keel & use up the last of the bottom paint Post-Launch, at pier: Test-run engine & gears Make 2x4 stanchion spacers for fuel jug lashing Launch dinghy & outboard Bend on genoa & sheets, mainsail & cover & lazy jacks Check all running & deck lights Tie-wrap length markers on CQR chain Rope to chain splice on both anchor chains At Mooring: Install Shaft-Lok’s new locking spring adjustment screw cap Mainsail battens: two (2) 29” x 2” and one (1) 32” x 2” Linda & Tom: +1-904-377-0527 = $30 Write return info on dinghy Make/install 2x4 spacers for fuel jug lashing station & lash fuel jugs Final GCSM Dockside Tighten autopilot belt Acrylic disc to seal forward hatch top Re-install wind generator New black tie-wraps on 3 uppermost SSB wire stand-offs New battens in mainsail & stitch pockets closed on main AND mizzen Re-bed stanchion over head locker leak Vaseline all snaps Stow outboard on rail, run dry Replace spring in generator electronic ignition Top off propane tanks Top off gasoline jugs Top off diesel New zip-wraps & tape on main spreader boots Spray sail tracks with dry graphite Dinghy patches Laundry Final (produce, etc) provisioning Car: change oil, store, jack up, cover. Bike, too. Clean/dry/stow dinghy Top off freshwater tanks Garbage ashore Set up staysail w/sheets Lay out jack lines In the DR Replace generator starter cord Patch dinghy tube leak New tie wraps on forward running light Cut out chafing section of roller furling drum cover Re-bed dodger top forward edge

Interior New Yanmar 54 HP diesel engine, installed Twin Racor fuel filters Rebuilt engine bed & mounts Engine gauges, not idiot lights, in cockpit Groco raw water filter –cleaned, re-mounted, new pipe fittings & hoses Ship’s bell New West Marine AGM deep cycle batteries: (5) Group 31 / 105 ah house bank, (2) Group 27  / 92 ah starter and windlass Rechargeable D-cell batteries and charger Installed water filter under sink (*#%!!!) Cut holes above water tanks with the jigsaw Disassembled and cleaned diesel heater parts Installed carbon monoxide detector Fabricated a sleeve for the broken diesel heater control knob Hinged engine box cover Disassembled and inspected diesel heater filter Installed high seas hatch board barrel bolts Installed companionway hatch intruder barrel bolt Painted portions of interior wood and all the mustard-colored Formica off-white Built a mounting system for the bin under the companionway Installed barrel bolt on hinged engine box Cleaned and unclogged diesel heater fuel system Fabricated hatch board stowage system Marine-texed holes in aft cabin Divided starboard wing of salon table Removed shower stall porthole Attached wood hinge mounting blocks to starboard wing of salon table with 5200 and installed locking wing hinges Designed/fabricated house bank battery compartment under captain’s bunk Scrubbed cabin overhead with comet cleanser Removed bilge blower ducts, vents & fan Removed transmission, had it rebuilt, and re-installed it. Cleaned the hatch glass Design/fabricate/install many plumbing upgrades New, HD hose for shower Repair shower nozzle (stop leaking) Design/fabricate sea chest Design/fabricate extensive re-plumbing, including PVC manifolds for several thru-hulls Canvas: V-berth cushions & seat cushion slip covers Main Salon new high-density foam settee cushions, back cushions just re-covered Aft cabin headboard re-covered Inflatable kayak as second tender Clean/dry water tanks Repair drawer support at workbench New fire extinguishers Install TV flat screen on hinge Adjust AirX internal regulator for 14.6v Rewire & remount electric bilge pump Run radar and windlass battery cables Clean sump & adjacent bilges Re-route refrigeration unit power wires Change freshwater filter elements Crimp battery some of the cable lugs Paint bilge sump Manifold for electric bilge pump, watermaker and head sink discharges Re-plumb electric bilge pump Frame floorboard hatch under galley sink Non-skid strips on salon c-way stairs Mount barometer/clock set Nav station flexible stalk halogen chart light Bilge pump & high-water alarms Tack hatch screen Velcro Adjust computer table Engine panel bilge switches warning lights Install windlass battery (shelf & box) in forepeak Wire new house, starting & windlass batteries Remove old batteries Build in VCR/DVD/flat-screen system Tightened porthole hinge tension Switch red 12’ 1g on Bank #2 for 2/0 red Connect all mast wiring Run 12-volts to woofer Crimp battery cable lugs: Red 12’ x 6g charger cable, (1) 3/8 dia. Red 6g to breaker, 5/16 dia. Black 6g to engine ground, 5/16 dia. Run 12’ x 6g charger cable to Bank #2 Red & Black 6g at Bank #3, 3/8 + 5/16 dia. Attach all Bank #3 cables New florescent light in galley Secure all fore/aft wires under cabin sole Install Shaft-Lok Mount & wire up radar display Refinish nav station bulkhead Remount & wire up Loran display Re-mount nav station instruments Remove/rebuild Walter V-drive (JB/Rick) Re-cover GPS companionway wire Re-wire main GPS (to Loran connection) Mount new dome light over nav station Mount/wire VHF external speaker 12v plug in nav station Run engine, tighten V-drive/prop shaft coupling bolts 25’ Duplex 10g, panel to mast terminal Wire mizzen masthead stern light w/disconnects & disconnect orig stern light Clean up more of Ben’s crappy wiring Test radar Slide on wire padding tubes in bilges Wipe down interior wood w/10% bleach Shower pan electric sump system Shower sump pump inline filter Mount handheld GPS holder in nav station Repair leak at water heater Double-secure throttle cable beneath pedestal Replace manual bilge pump hose Grease/oil steering cable sheives Wire-brush, Ospho, prime, paint fuel tank rust areas New lazarette forward bulkhead Stern anchor locker/shelf in lazarette Line hanging bars in lazarette Paint port shelf in lazarette Salon hanging locker, high shelf 12” x 34” Flush out holding tank & hoses Repair/service holding tank Y-valve Summer-ize Dickenson heater: - Run fuel line empty - Drain, flush & refill fuel tank - Change filter element - Clean combustion chamber         Cut off port settee cushion’s useless aft outboard corner and install fiddle to create a storage space there Replace all water tank deck plate O-rings & lubricate the new ones Replace old lead acid starter battery with new AGM Group 27 Run/secure deck washdown feed hose & pos. power wire Install small compass at nav station Install small compass by captain’s berth Replace plywood in rotted forward starboard inboard salon overhead panel Clean bilges (once again!) Replace galley sink faucet plumbing & drain hose Wire laptop to movie speakers Remake seawater intake manifold Plumbing Revamp Identify & label water heater manifold hose destinations Disconnect/remove toilet and forepeak sink hoses Reconfigure water heater manifold Remove holding tank, flush clean, take to welder to add ports as per re-design Replace all water tank discharge hoses – 5/8” ID, 42’ total Secure deck washdown feed hose & all loose wires beneath cabin sole. Clean up & secure everything else under there and remove useless crap. Remove VacuFlush toilet & system components (accumulator tank, electric pump, etc) Replace water heater main feed hose Wedge/shore up cabin sole where it dips aft and to port of the mast. Install inline T’s & short, plugged hoses for draining water tanks into bilge sump Install wicks to make keel-top bilge drain aft Remove old holding tank vent & deck pumpout hoses Secure/hang wire runs starboard of sump area Holding Tank: Pull out tank & flush clean Welder:    add new threaded entry to upper aft starboard side    replace existing single vent hose nipple w/two ¾” FIP for two ¾” hose barbs    Plug old fwd entry hole Install 1½”nylon hose barb in new entry port Install (2) ¾” nylon hose barbs for ventilation hoses Re-install holding tank with re-conditioned Y-valve Install (2) new ¾” vent hose topsides fittings Install (2) new ¾” Series 148 Vinyl vent hoses (13’ & 14’)  = 30’ x ¾” ID New 1½” ID S148 Vinyl hose for deck pump-out overboard pump-out, toilet to holding tank & toilet overboard Install all new hoses with no low spots where sewage can stand Design/fabricate/install seawater intake manifold & mounting block with inline filter for deckwash pump Rebuild Perko raw water strainer for use with seawater manifold Design/fabricate/install bilge mounting pad for manifold’s Perko raw water strainer Install New Toilet on ¾” starboard pad All new plumbing, PVC & hose Anti-siphon loop mounted above/outboard of toilet for seawater intake Y-Valve for toilet discharge – under sole near seawater manifold 1½”-hose anti-siphon loop high up under galley sink for toilet direct overboard discharge Galley foot-pump freshwater/seawater Y-valve Clean up manifolds & fittings under galley sink (larger outlet elbow on big filter!) Spare water pressure pump Open up dead space outboard of shower Cut opening to dead space outboard of shower & install access hatch Refresh, re-mount shower faucet New hose clamp on shore water connection inside port cockpit locker, w/pipe dope Install Heart power inverter Build custom nav station shelf for sextant Grind off protruding screws in aft bins under V-berth Wire inverter to house AC system Disassemble/clean heater door Fabricate mount for wind generator off switch & amp meter. Wire wind gen to batteries thru off switch, amp meter & breaker/fuse Repair engine enclosure screw mount Replace salon 12v Hella fan Reverse wires on wind-gen amp meter Change drinking water filters Rewire aft cabin clock for remote battery 2nd latch for flatscreen Double shock cord retainers on upper mid-companionway shelf 5 Acrylic panel shelf retainers New Delco CS-130 105-amp alternator Replace broken head door latch w/alternate Brendan wired and Tor mounted (1) the Xantrex smart charger and (2) the radar’s external buzzer Change engine oil Wired radar external buzzer on/off switch Checked out radar, reset default heading Hauled-Out: homemade porta-potty Cut/install hose to rinse bilge sump Velcro tabs under salon cushions Velcro salon overhead hatch screen Check water-tightness of water tanks inspection ports Replace Shaft Lok locking nut Replace fridge drain hose Icebox compartment: complete insulation upgrade Rewire compass light Augment fastening of V-berth shelves to bulkheads fore & aft with custom stainless steel L-brackets, thru-bolted Replaced original West Marine AGM deep cycle batteries with new: (5) Group 31 / 105 ah + (2) Group 27  / 92 ah Compartmentalize salon electrical locker Installed PowerSurvivor 12V watermaker Remount aft cabin Ikea clock Test-run/pickle watermaker Make template for new aft bunk mattress New aft cabin mattress! Install (3) bunk lee cloths / tie points St. Martin: Replace salon light bulb Re-bolt salon table foot (Davina) Dow 111 salon deck hatch gasket Clean windlass connections in chain locker Tighten Shaft-Lok shaft coupling & adjust cable Replaced stripped support strut on forward hatch Cut cabin sole access hatch above ShaftLok Mount can crusher Mount bag holder Change all water filters Change engine oil & transmission fluid Install new Shaft-Lok cable Modify wind generator stop switch & reconnect Replace 12v cabin fan in salon Mount automatic antenna tuner Installed SSB/HAM radio rig incl. tuner, counterpoise & antenna connection. Move aft bunk lee curtain forward 8” Repaired wind generator amp meter Store shotgun for quick access Tighten engine fan belt Replaced broken cooling fan at fridge compressor. (Well, Terry replace it.) Install new 60A battery charger, incl. all new cables Main companionway Velcro/screen Prime/paint dish rack Move primary anchor rode forward Install new handheld VHF Cut out forepeak sink & faucet Replace broken head faucet Build tool storage bin under workbench counter Scrub salon cushions clean New, longer toilet pump handle Install new antenna tuner Install barrel bolt lock on main companionway Eileen Canvas:  Slip-cover for settee bench seat cushions & Stop settee cushions from sliding Make canvas duck slip covers (w/molas) for 2 throw-pillows Sunbrella cover for life raft New cover for starboard center salon backrest cushion Bimini filler mizzenmast wrap strat + 4” Slipcover flaps for salon backrest cushions Sew molas onto end cushions Ospho/prime/paint rear motor mounts Tighten starboard rear motor mount bolt SSB up & running and programmed Wash saloon cushions Repair water jug leak w/5200 Wire on head door hook Tigthten top companionway ladder step. Clean fridge, clean bilge Round aft corner of port salon bunk board &  shave the top edge to a softer round. Pickle watermaker GCSM Boat Yard Work List – Spring 2011 Pickle watermaker Change engine oil & transmission fluid Pre-Haul-Out: Set up porta-potty Empty/clean water tanks Repair broken teak trim in salon Fix leak under head sink Wash bilge sump Clean/dry water tanks Remove bilge sump drain plug Remove/clean engine sea strainer Clean/flush seawater intakes, manifold & hoses to all manifold users Remove/clean manifold sea strainer Screen bilge sump drain plug Replace spring in Shaft-Lock Cole: Change V-drive oil Clean Raycor & change engine fuel filter Leaving: Housecleaning Lead shower sump to bilge / leave shower porthole open Wrap mattress & lash on van roof rack 12v clamp-on car fan to van Open all floorboards & lockers Open head porthole & head door GCSM Boat Yard Work List – Fall 2011 Clean bilge Reconnect shower drain Sunbrella from Sailorman (for settee slip covers) Replace shower sump pump Clean settee stained cushions Secure Shaft Seal rotor w/new set screws when they arrive (compress bellows 1”) Clean & spray-protect windlass connections Clean chain lockers New hinges on toilet seat Check both GPS’ Cut new shower curtains Install new VHF Remove/clean/’re-install diesel heater fuel tank, line system & heater valve Replace noisy fridge fan Mount Blue Sky booster/controller on bulkhead aft of house battery bank Re-weld top c-way step & others – Coats’ machine shop Wire solar panel to house battery bank via booster/controller Post-launch, at pier: Burp Last-drop shaft seal to let water in Bleed intake manifold House cleaning Align prop shaft coupling - Cole Scrub, dry & stow porta-pottie Clean SKS with Rick Make hanger latch to store SKS Grind off bracket sharp edge above Shaft-Lok New O-rings in galley faucet Final GCSM Dockside Charge up fridge, appliance batteries, etc. 12 more boxes ammo for SKS Email to everyone to stop emailing me for 2 weeks Lee cloths on bunks Download PassageWeather.com In the DR New wire terminals at windlass control box New switch for wind generator New latch magnet on head door Fix leaky galley foot pump faucet New long/short pins set in Shaft Lok Barrel bolt (inside) & new magnet on head door New retainer cords on salon flag shelf