Introducing Katie-J

Post photos and descriptions of your ongoing projects here. No project is too big or too small.
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pmnfernando
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Re: Introducing Katie-J

Post by pmnfernando »

quick update about the rigging

vectran covered with nylon/polyester sheat, whipped at both ends.
this will be further covered with Marlow dyneema hollow plait chafe protection sleeve.
WhatsApp Image 2022-05-10 at 8.01.13 AM.jpeg
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Re: Introducing Katie-J

Post by CapnK »

Ah hah! I was wondering how you terminated the line... then looking close at this part I see you are making a small eye splice over this metal plug (for lack of the proper term) which I've highlighted with a yellowish color, and that fits inside the terminal - is that correct?
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pmnfernando
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Re: Introducing Katie-J

Post by pmnfernando »

yes, thats it!
they call it the bone and is does look like that, very smooth little piece.
the eye is done as snuggly as possible
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Re: Introducing Katie-J

Post by CapnK »

Is that end for the mast tang(s)? If so, how will you be tensioning the line? I've seen the Colligo deadeyes, they look nice but are pricey. Saw a post somewhere and it was a guy using a fence tensioner, like the last one shown in this video. I bought a cheap plastic version of that to try out on my Caprice dinghy, but that project is for *after* Katie. :)
Kurt and Barque, the CrewDog.
Sundance, '71 A-30, #429 <- Home!
Katie Marie, Ariel #422 <- Soon Home!
Melelani, Islander 36 (shoal) <- For Sale

sailFar.net - Small boats, Long distances...
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pmnfernando
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Re: Introducing Katie-J

Post by pmnfernando »

i will be installing standard turnbuckles.
they are way more convinient to setup and tune than old style tensioning purchase systems - even if using synthetic fibres-
where you winch up to get the tension etc etc etc.

both terminals are the same because both turnbuckle and tang are a toggle connection

i will post photos with all the gear, as the turnbuckles for the main stays are different from the babystays.
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Re: Introducing Katie-J

Post by pmnfernando »

rudder bearings

hopefully on my next refitting season i will reinstall the rudder.
Im having the rudder post/ spade fin structure done new by a metal shop.
it consists of 52 mm diameter solid shaft at the top of the spade, which then tapers into a smaller diameter (cant remember it now) being finally machined to a square profile to accept the tiller head piece, where the tiller bolts.

the rudder shaft is inserted from below into a rudder post which runs the entire freeboard up to the exit point inside the cockpit, so there arent any glands or shaft seals, its completely encased. the rudder post is made of metal and glassed to the hull. (dont know what metal, maybe iron, galvanized?, it does seem to be original)

when i removed the rudder there was no bearings, or bush bearings, it was just metal on metal, hence why the stainless was in bad shape

the idea is to replace the metal rudder post by a wound fibreglass tube, with a G10 reinforcing collar - both at hull and cockpit level- and glassing over all that with biax.

I obviously want a separation between the shaft and the post and was thinking of having a delrin bush bearing machined.
My question is: should i leave to spin freely at the bottom , ie using it as a spacer/bearing or should it be locked in?
for the top bit im not worried since some arrangement with a couple of grub screws can be done, but at the bottom i wouldnt want to drill holes (no more watertightness), or epoxy the spacer/bearing (easier to replace in the future).

thanks for your input
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Re: Introducing Katie-J

Post by atomvoyager »

I don't see why you can't let the lower bushing spin free. I used a PVC tube that just happened to fit for that purpose in the past.
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Re: Introducing Katie-J

Post by pmnfernando »

my issue is with the delrin spinning freely over the fibreglass tube and the resulting wear
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Re: Introducing Katie-J

Post by atomvoyager »

I understand that but I haven't seen that problem.
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Re: Introducing Katie-J

Post by pmnfernando »

reassuring to know that, means that i can proceed as planned!
thanks
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Re: Introducing Katie-J

Post by pmnfernando »

trying to keep things ticking forward since i cannot work on the boat due to weather

Been designing a composting toilet, based on the C-Head shape
Its pretty much a copy of its overal shape, but im making sure its churning mechanism is way more complicated, so im going in the right direction! hahahaha

solids bucket its an off the shelf unit (5 gallons)
pee container is designed by me. 4.3 litre (1.1 gallons)
toilet seat shaped to the toilet, unlike the C-head design where they´ve maintained a curved shape, making it weird in my eye.

the toilet is going to be built of 3 mm G10, epoxied and glassed
compost toilet.jpg
3D view
composting toilet 3d view.jpg
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Re: Introducing Katie-J

Post by pmnfernando »

Got around to make a template from which a 6mm G10 windlass deck plate will be cut

Wanted to have a nice clean surface to mount the windlass and delete whatever existing camber might be.
It will also help disperse the loads

An underdeck 30mm G10 spacer will also be cut, but in a square shape to give enough meat to fasten the windlass

The deck plate has a 15% bigger footprint
WhatsApp Image 2022-06-07 at 4.37.55 PM.jpeg
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Post by pmnfernando »

And been designing the fridge/freezer box to eventually accomodate a CoolBlue units.
Got it to 7.3 cubic feet, approx 200 litres, which is the advised size for a fridge/freezer single system.
this size account for 4 inch insulation on the hull topside face, and inside face, 3 inch from the top, and 2 inch at the fore and aft face.
ice box 3D.jpg
Top view of the countertop
In yellow you will see the sink footprint, and to its right side the 2 burner stove been designed by me (more on that later)
in green its the eutetic plate vertical footprint and purple shows the opening
countertop top view.jpg
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Post by pmnfernando »

2 burner stove

this is one of them multi fuel stove.
the plan is to install 2 on a SS plate
this will enable me to use multiple petroleum based fuels, avoiding the propane trap and since it is portable if im ashore camping i can easily cook a meal.
WhatsApp Image 2022-06-08 at 7.47.11 PM.jpeg
so far i think i will keep the dimensions at 500 x 170 mm (6mm thick SS) for the stove top with welded 3mm thick wings to allow for gimbaling.
Maybe 6mm is overkill but i really dont want it to bend nor do i want to weld a reinforcing stringer underneath

i still have to figure out a quick release clamping solution for the hob itself, a fiddle suport arm and pot base, but something will come up
WhatsApp Image 2022-06-08 at 7.47.11 PM (1).jpeg
WhatsApp Image 2022-06-08 at 7.47.11 PM (2).jpeg
WhatsApp Image 2022-06-08 at 7.59.52 PM.jpeg
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Re: Introducing Katie-J

Post by CapnK »

Re: Churning mechanism - I've been pondering variations for years. How does/will yours work, it appears to need to have a hole in the bottom of the solids container...?

Re: Stove - I had the same model stove, bought for the same idea and reasons. :) Great equipment! For consideration: One thing I found in testing is that the gas bottle needs to be as far away from heat as is possible, and/or have a heat shield.

Works fine if you are doing a typical backpacking meal and need to boil 2 cups of water as fast as possible, but longer cooking times can get the bottle hot enough that it worried me that it may vent fuel unexpectedly, or even explode. Also, a large pot sitting on the burner tends to reflect heat back/down towards the tank, which I think exacerbated the issue.
Kurt and Barque, the CrewDog.
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Katie Marie, Ariel #422 <- Soon Home!
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Post by pmnfernando »

i will apply grp cloth to the inside of the bucket, having previously applied in place a piece of plastic which will make up for the volume , occupied later by the central sprocket,

this way, when i effectively cut the bucket to make way for the chain connecting both sprockets, all solids will be contained by the grp lining. there will be a 50 mm difference between the lower sweep height of the churning paddle and the bottom of the bucket, but i will fill that with foam and glass it. will lose a bit of volume but im ok with that. ie, i will be raising the bottom of the bucket.

thanks a lot for the feedback about the stoves. ive never used them before, just bought it for this specific project.
i think the heat reflection by the pot will be mostly contained by the 6 mm thick SS plate, but your point about the proximity of the bottle to the hob is indeed making me rethink the current spacing.
the issue is the hose is not that long, i went to their website i couldnt find a bigger lenght, nor do they do a Y valve, where one bottle could feed 2 hobs. that would be the ideal solution (not sure if the one pressurized bottle could feed 2 hobs though)

maybe a fibreglass elbow like the ones used to route exhaust hoses will do the trick as a heat shield.
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Re: Introducing Katie-J

Post by CapnK »

I first tried it with an all-in-one Coleman Exponent Multi-fuel stove. A friend had one that he used for years on backpacking, biking, and kayak trips and it impressed me. But the first time I used a big pot and long cooking times, it started leaking vaporized fuel at the built-in pump - just inches from the flame. Yikes!

Then I bought an Optimus like you have - it's a very nice piece of gear. It was eventually lost in a storm when my dockbox got dumped into the river, but I had tested it and it worked well. I'd made for it a heat shield of sheet metal, after seeing how well that worked with just a 1/4" standoff from the bulkhead next to my woodstove which could easily get to several hundred degrees.

Prior to the heat shield, the bulkhead by the woodstove would get unpleasantly warm, even on the side *away* from the stove. I thought that too hot, if not an eventual fire hazard. After putting the sheet steel there, the bulkhead never even felt warm.

All this to say that you may be able to get away with just that, a simple piece of shielding. If you wanted to be *sure*, then use 2 pieces of AL or SST with 1/4"- 1/2"" fiberglass batting insulation sandwiched between. I think would work wonders and be simple to make.

Looking forward to seeing more of the churner. :D I've spent many hours trying to figure out how to do one that works horizontally, as that would seem to be the best way to make it churn most. Lately, though, I've been not churning, instead just giving any new solid deposits a light dusting of coir. That actually seems to work well.
Kurt and Barque, the CrewDog.
Sundance, '71 A-30, #429 <- Home!
Katie Marie, Ariel #422 <- Soon Home!
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pmnfernando
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Post by pmnfernando »

But the first time I used a big pot and long cooking times, it started leaking vaporized fuel at the built-in pump - just inches from the flame. Yikes!
....damn! thats scary. dont wanna go thru it for sure!!

Upon research i came across the Polaris and the MSR. Those were the standouts and both have big fans behind them, if i remeber correctly i think i went with the polaris because the pumping mechanism is stronger than the MSR, though in some aspects it is said the latter performs better in an overall sense.

G10 actually has very good heat resistance and it is used in shielding.
I was aiming for the smaller footprint stove i could get, but i might have to modify it, specially because i will be carrying a Coleman foldable oven which will overhang by about 75 mm on both fwd and aft face of the burners (relative to the user). using this oven is the only way i have to avoid buying a full on stove/oven unit, which would simply eliminate all the space for my fridge.
Since the shielding will take up more space i guess the lenght of the stove will increase by 50-70mm.

About the churner, in my mind there is no reason why it shouldnt work, i mean, we are talking about 2 sprockets and a small run of chain. Experience tells me that it wont be that straight forward and there will be unforeseen snags.
I ve also read that the moment one separates liquids from solids churning isnt actually needed, as you stated.
So maybe im just complicating things for the sake of it. i will be posting photos of the attempts aniway
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Re: Introducing Katie-J

Post by atomvoyager »

We've used this stove top oven on several boats and it works pretty good if you can adapt your recipes to the donut shape:
https://www.omniasweden.com/us/
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Post by pmnfernando »

heard very good things about the Omnia ovens, but how do you cook pizza on it!! hehe
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Post by atomvoyager »

Yes there are some recipes you might not want to do that way but pizza is an easy one we've made with the Omnia. Here's an article on that. There are a surprising number of things you can bake in that donut shape.
https://vanlifeeats.com/best-ever-omnia-pizza-recipe/
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Re: Introducing Katie-J

Post by CapnK »

I've always wanted to try one of those...

As an Internationally Recognized Aficionado and Expert on Pizza :mrgreen: I can tell you that it is possible to grill your pizza in a rail mounted propane BBQ.
Kurt and Barque, the CrewDog.
Sundance, '71 A-30, #429 <- Home!
Katie Marie, Ariel #422 <- Soon Home!
Melelani, Islander 36 (shoal) <- For Sale

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Post by pmnfernando »

Bulkhead reinforcements

Been thinking about what solution to choose, moving forwards.
Although i wanted to keep the goalpost structure i think it takes too much space.
Since the goalpost was bolted to the main bulkhead i dont think it was actually transfering the load to the hull. the load was being transfered to the bulkhead instead.
It was also bent in the middle, meaning that it failed the objective of sustaining the load where it matters most: directly beneath the mast step.

I have designed a new arrangement, which is displayed in the photos below
Everything is 6 mm thick SS plate welded
Both reinforcements units, fwd and aft, will be bolted together, thru the bulkhead
aft is green
fwd is yellow
bulkhead in red.

you will notice the fwd section is slightly longer than the aft one, that is due to space available.

To install i would firstly apply a couple of cloth layers to the cabin top (glasssing upside down is tricky but doable).
Both units (being previsouly laminated with packing tape) would be placed correctly and bolted together as close as possible to the cabin top
Thickened epoxy would be squirted to fill the gap between the units and the cabin top.
Upon curing the packing tape would enable the release of the units for future handling.

I think that welding those triangular brackets will be more than enough to counter the downforces exerted by the mast.
it is a structure that i would make part of the boat´s interior, as they would be polished, it not something i would conceal (because that entails more work covering it up and more nooks and crannies that im trying to avoid), plus making small 12 mm holes at the correct spacing will enable me to use a biner or shackle and affix somethiing to it (a hammock, curtain, etc)
BULKHEAD REINFORCEMENT .jpg
BULKHEAD CREINFORCEMENTS 3.jpg
BUKHEAD REINFORCEMENT 2.jpg
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Post by pmnfernando »

Berth cabinet

this is the berth cabinet solution.(untill i change it again)
its the same both port and stb (std is the one depicted)

there is a kind of central console, so to speak, that ive opted for because one is either going to sleep head first or aft, so those spots are really where you want a roomier feel. aniway a rough template will be made to make sure i have enough space at my waist to feel confortable and it will be a matter of adjusting the depth of the cabinets.
all spaces will have a latched door
BERTHS CABINET.jpg
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Post by pmnfernando »

Engine rebuilt

Got a forced week off work, due to Covid, this past week, and full on lockdown starting next monday for the entire next week. Yeah, living in China in 2022 is like 2020...

Aniway, decided to get started on the engine.
It has been off the boat for almost a year, and was really dirty from all the grinding and sanding on the interior before i got it out, so i basically took a toilet brush to it, with a general cleaner, gave it a good brushing, and literally rinsed it inside the shower booth (i taped the entry points, but some went into the flywheel housing, but just a bit.

before shower3.jpeg
before shower2.jpeg
after the shower
after shower2.jpeg
after shower.jpeg
some paint flaked of, and the majority of the dirt came out.
Last edited by pmnfernando on Sat Jul 09, 2022 10:14 am, edited 1 time in total.
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Post by pmnfernando »

after transfer pump and zinc removal.jpeg
cylinder head interior.jpeg
cylinder head.jpeg
flywheel.jpeg
headgasket.jpeg
interior valve cover.jpeg
overall view inside timming crankcase.jpeg
valve cover and start motor removed.jpeg
valver spring rockeer assembly.jpeg
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Post by pmnfernando »

these photos are just the "unexpected" so far.

look at the state of this bolts, they look new! thermostat housing
thermostat housing bolts.jpeg
no thermostat was found, this one was intriguing. judging by the amounf of rust, debris, and scale i say it corroded inside and it was never replaced
thermostat.jpeg
i think the same happened to the anodes, both of them (anode housing)
second anode housing.jpeg
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Post by pmnfernando »

any thoughst for a serious descaler?
from my research it seems Muriatic acid (anywhere from 50 to 30% dilution) will do the job with a soaking time of 30 minutes, followed by imersion on water plus baking soda to neutralize the reaction.

the water jacket is Seriously full of rust and deposits
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Post by pmnfernando »

engine disassembly

oil sump and pickup removed
oil sump and oil pick up removed.jpeg

fwd and aft pistons
aft piston.jpeg
fwd piston.jpeg
injectors
injectors.jpeg
mixing elbow with completely obstructed and carbonized breather hole
mixing elbow with completely carbonized breather hole.jpeg
and the "unexpected" section

piece of hose living inside the oil pan, pretty hardened up
piece of hose inside the oil sump.jpeg
big calcified lump against a 12 mm socket for scale
calcified deposit removed from water jacket 12mm socket for scale.jpeg
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Re: Introducing Katie-J

Post by CapnK »

I keep all of my spare hoses and various metal lumps inside the oil pan...

:mrgreen: :mrgreen: :mrgreen:
Kurt and Barque, the CrewDog.
Sundance, '71 A-30, #429 <- Home!
Katie Marie, Ariel #422 <- Soon Home!
Melelani, Islander 36 (shoal) <- For Sale

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Post by pmnfernando »

moving on with the engine job

cylinder head
cylinder head before clean up.jpeg
after about 3 hours of scrubbing with those green kitchen scoring pads and diesel
cylinder head cleanup.jpeg
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Post by pmnfernando »

yesterday hit a dead end because i just couldnt remove the drive disk
used a heat gun at 600C (thats what the digital meter was saying) for 20 minutes, got the whole thing hot as hell and it didnt moved

had to take the block to a friends place and he took it. dont know what he did but its out now

drive disk
drive disk.jpeg
drive disk and flywheel removed
drive disk out and flywheel.jpeg
i wont go any further in terms of disassembling the engine (not that im that far off of completely take it apart...haha) the crankshaft, camshaft are all good, no need to to mess with that

i will remove the housing to be able to deep clean it and to acess that side of the block
flywheel housing.jpeg
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Post by pmnfernando »

cleaning the inside of the flywheel case

before a bath in paint stripper
the alu is corroded although it is worse at the bottom
flywheel case before paint remover.jpeg
interestingly the paint stripper was able to remove the corrosion from the top section
flywheel case after paint remover.jpeg
what was left was mechanically removed with a brass wirebrush on a driller
flywheel case after paint remover and wire brushing.jpeg
flywheel case exterior before paint stripper
flywheel case exterior before paint remover.jpeg
after paint stripper
flywheel case exterior after paint remover.jpeg
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Post by pmnfernando »

oil sump before paint stripper
oil sump before paint remover.jpeg
after paint stripper
oil sump after paint stripper.jpeg
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Post by pmnfernando »

timming case before paint stripper
timming case before paint remover.jpeg
after paint stripper
timming case after paint remover.jpeg
removing the gasket
gasket removal timming case.jpeg
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Post by pmnfernando »

engine block before cleanup
engine side before wire brushing and paint remover.jpeg
engine side before wire brushing and paint remover 2.jpeg

engine block after clean up
clean engine block1.jpeg
clean engine block 3.jpeg
clean engine block 2.jpeg
Last edited by pmnfernando on Sat Jul 30, 2022 8:40 am, edited 1 time in total.
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Post by pmnfernando »

engine top before cleanup
engine top before cleanup.jpeg
after cleanup
engine top after cleanup.jpeg
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Re: Introducing Katie-J

Post by pmnfernando »

another X file

see that small rod-like thingy inside the water jacket?
have no idea what it is
on the engine top there is a round opening that is part of the water circulation circuit, if i blow air thru it, it comes out from where that rod appears to be stucked/mounted.
no mention about this on the manual
another x file.jpeg
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