KISS my Cleats!  We’ve been Double Crossed!

KISS my Cleats! We’ve been Double Crossed!

Another fun week for Team Möbius as they kicked into their mass production mode manufacturing all the shiny new double cross bollard style cleats outside and continued gluing down miles of EPDM insulation on the inside.  Let’s check it out.

IMG_20190208_104321You are looking at the production coming out of the cleat factory with most of the finished double cross bollard style cleats stacked up and waiting for final welding into the Rub Rails along both sides. 

But let’s review what led up to this …………….

IMG_20190125_125409You will recall these four very different and slightly more eXtreme style and size of  “Crane cleats” which were all welded in a few weeks ago and which are literally strong enough to lift the whole boat by crane, should the need arise. 

These four Crane Cleats enables quick and easy lift and load of Möbius by crane onto any container or cargo ship but we will most likely use them when we need to be hauled out while in very remote and isolated parts of the world, our favorite, and there are no shore side facilities or marinas for hauling out. 

We have run into this situation in the past in places such as the Marshall Islands, Vanuatu, Tonga and parts of Fiji and found that these areas all tend to have commercial shipping or shoreside building projects which have huge cranes  which can easily lift our svelte 45 tonnes from the water to a cradle or pit we can create ashore. 

These Crane cleats will also come in eXtremely handy in the not so unlikely event that we need to haul Möbius out for one of our extended trips to be with our Grandkids and other family and friends while we happen to be in a cyclone prone time and area.  Another experience we have had several times in our boating past.  Once the Crane or other lifting method hauls us out onto the hard, aka land, we can then use these same cleats to tie Möbius down to huge stakes we drive into the ground to help secure her in what could be winds in excess of 200 MPH.  Ask us how we know?

Double Bollard alternativeFortunately that scenario doesn’t present itself too often and even for our eXtremely over engineered XPM eXtreme eXploration Passage Maker, these Crane cleats were Papa Bear size and not the just right Goldilocks fit for the more common needs we’ll have for secure cleats when docking, fueling up, rafting alongside big commercial boats and the many other situations where we need to have super secure lines between Möbius and docks, piers, pilings, etc..

Double Bollards Drawing v1.1After considering several different cleat styles we have used over the years we decided to go what I believe is technically called a “double cross bollard cleat” which is a mouthful so I’ll just refer to them as cleats now.  These are in keeping with our KISS approach to Keep It Simple & Safe and we have found them to best handle the largest range of types of lines, sizes and options.  

So I fired up Fusion 360 and quickly created the 3D model of the just right sized cleat for Möbius you see above and and then the and 2D drawing on the left.  Good thing I am no longer teaching draughting as I would not have given this drawing a very good grade drafting convention wise! 
IMG_20190207_153419However it got the job done and provided all the dimensions and details for our machinist to quickly crank out the three individual parts that make up these KISS cleats with their nicely rounded solid end caps.
IMG_20190206_125353Which fit together and are quick tacked like this.
IMG_20190207_153352We need 12 of these cleats all together so Uğur quickly created this jig to hold each of the two 60mm/ 2 3/8” vertical bollard posts and the 30mm / 1 3/16” cross bar in just the right position and cranked out all 12 of them in the flash of his MIG welding gun.
IMG_20190207_153340and stack them up ready for Sezgin to take over with his
IMG_20190208_170531own trusty little jig he made up to hold them while he laid down his beautiful TIG welds around each intersection of the cross bars to the bollard posts.  

Check out this week’s video summary to see Sezgin in action!
IMG_20190208_104315And soon this pile formed behind him.
IMG_20190204_133042While Sezgin was busy at the bow Uğur, Nihat and Mehmet got to work on the last length of Rub Rail on the aft end of the Starboard side.   The Rub Rail you see laying on top of the deck here was supposed to have gone in here last month but the company that did the bending of these 10mm plates somehow bent this one “backwards” or inside out and the new corrected one just arrived last week.  It is now all fully welded in place to complete the full set of Rub Rails down each side and they can now get to work cutting the holes through for each of the 60mm pipe sockets that hold the stanchion and railing pipe

IMG_20190205_110646Down below the deck Sezgin has finished fully welding in all four of those massive Crane Cleats we saw above where they wrap around the tops of the 12mm frame plates, so they are now an integrated part of the hull and ready for action.
IMG_20190205_110243Dropping down one level to the Workshop and Engine Room area we find Himi in the foreground who is actually our electrical technician and Faruk who is the head of Naval’s Insulation & Composites team busy in their own mass production factory as they cut miles of the 50mm EPDM foam insulation and glue it to all the interior aluminium surfaces.
IMG_20190206_130112Himi is very motivated to get this all done so he can install all the wire trays he has cut and ready to go and then get started with installing even more miles of electrical wires and cables to carry all of Möbius’ electrons traveling at 12, 24, 120 and 240 volts as well as all the data dashing back and forth for all our instrumentation, navigation and communication.
IMG_20190209_133207The photo above is looking aft along the Port/Left side and this one is looking forward along the Starboard/Right side of the hull.  The Engine Room is on the far left and the 550L Day Tank will be going in at the far end against the WT Bulkhead with the Guest Cabin & Christine’s Office on the other side.
IMG_20190209_112611And finally I will leave you with this zoomed out shot taken from up on mv Legacy, the ship sitting in front of Möbius.  Christine and I spent the day, Saturday, in the yard aboard Möbius working out some of the interior cabinetry details and also took some time to go through Legacy to see all the progress on her major refit.  This shot is taken while we were standing on the bow of Legacy looking down at our beloved  Möbius and thought you would enjoy this perspective.

Demir, Yigit & Mert Feb 7, 2019Of course we can’t leave you without your weekly fix of cuteness from the Dincer twins, Yiğit and Mert and their adoring big brother Demir so here you go!

Hope you enjoyed this week’s progress update and thanks so much for taking time out of your busy day to join us.  Please add your most valued and appreciated comments, questions and suggestions in the “Join the Discussion” box below and I’ll do my best to get back to you ASAP. 

And last but hopefully not least is a very quick video synopsis of this week’s progress building mv Möbius here at Naval Yachts.

Möbius Arch – Turkish Map Fold style

Möbius Arch – Turkish Map Fold style

Many of you will be familiar with Turkish Map Fold style books if not by name perhaps by having one of these as a map when traveling. 

Turkish Map Fold 2Turkish Map Fold
Team Möbius got our Arch on Möbius in place this week and the all the many functions we have been able to incorporate into the design of this arch it reminded me of the Turkish Map folded books and maps I’ve had and always been fascinated with.  Seems only appropriate that our Turkish built boat would have a Turkish Fold style Arch and hence the title for this week’s update.

You may recall seeing this little animation in an update a few weeks ago and show is always better than tell so I’ll use it again to help you understand how our folding mast works.  Burak kindly put this together for us as we were testing out different configurations and dimensions of this whole system. 

The video makes it all look very simple, and it is remarkably simple but getting the geometry just right so everything fits and clears and the roof ends up in just the right spots when fully up and fully down was tricky and hats off to Dennis, Yiğit and Burak for getting this to all work out so well.

We have gone to this significant amount of work to design and create this folding Arch & SkyBridge roof in order to give us two very significant features or modes:

1.  Canal Mode where by lowering our Air Draft, the distance from the Water Line to the top most part of the boat we will be able to cruise in areas such as the canals or small inland rivers and water ways which have low fixed bridges you have to be able to pass under.   Our Air Draft with the Arch and roof folded down will be about 4.2m/13’ 6” compared to about 6.4m/21ft to the top of the raised Arch, and then the Paravane poles add about another 2m/6.5’ on top of that.

2.  Hunkered Down Mode where we can dramatically reduce our windage, the side area, when we are in areas during cyclone and hurricane season.  Christine and I have spent quite a bit of time in such areas both together and when we were single handing so we have first hand experience with the power and the danger which these severe weather patterns possess such as the 285 km/h winds we saw when Cyclone Winston hit us when we were hauled out on Learnativity in Fiji in 2016.  By dropping our height and essentially eliminating our SkyBridge and putting plywood or Lexan storm coverings over all the Pilot House glass we stand a much better chance of surviving such forces of nature with the least amount of damage possible.

IMG_20190123_113739You saw some of the components of this arch being prepped last week as Sezgin and his TIG welder made quick work of welding all the many joints where the various diameter pipes all connected.
IMG_20190130_122551Those have all now been lifted up onto the SkyBridge for assembly into the finished arch.  Here is one side of the vertical legs of the Arch being stood in place.
IMG_20190130_150553and tacked to the upper half of the big hinge plates on either side.
IMG_20190129_135357Uğur and Nihat finished cleaning up the upper arch member with brass wire wheels….
IMG_20190130_150519….. and set it atop the two vertical legs, got everything all squared up with the laser level and tacked in place.
IMG_20190130_150433Stepping back on the Aft Deck you can see how the vertical pipe legs of the Arch continue below the hinge plates to transfer most of the loads down to the eXtremely strong hull framework and make this arch essentially part of the hull itself.

The vertical pieces under the Aft Deck roof are temporary braces to maintain its location prior to having its supports down to the Engine Room Vent boxes a bit later.
IMG_20190130_150239Looking up from the ground will give you another perspective on the Arch in place as it awaits fitting the SkyBridge roof structure and testing out the whole folding mechanism.
IMG_20190130_150647This view from the forward Port corner of the SkyBridge provides a good perspective of the size and scale of the Arch.  The rectangular opening in the middle is where the comfy Captain’s chair will sit to create the upper Helm Station and the circular stairs you’ve seen in previous weeks is over to the left in this picture and leads down to the Aft Deck.
IMG_20190130_150841Moving aft and standing just behind the Arch provides another view of the SkyBridge layout.  The rectangular holes in the bottom of the Arch top plate creates room for me to work on the many items mounted up here such as Radars, AIS, GPS and many antennae.  There ware slots in the pipe which you can see in the photo above where all the wiring will be very safely carried down inside the Arch tubes to the electrical panel that sits down below the deck where the Port Arch legs attach.
IMG_20190131_110010With the Arch all tacked up we could carefully fold it down for the first time and tweak the alignment and fit to get everything just right.
IMG_20190131_104205This is about how the Arch will sit when it is fully folded down with the SkyBridge roof fame attached.
IMG_20190131_131334From a distance and slightly under water level it looks like this.

Next up we will lift the SkyBridge roof fame you saw being made a few weeks ago, lifted up and fasted to the Arch so we can test out the whole Turkish Map folding system.
IMG_20190128_115039Never being ones to rest, Uğur and Nihat were also busy folding up the 6mm aluminium plates that will become the two large Engine Room vent boxes on the aft deck.
IMG_20190129_113133This is the ER vent box on the Port side …..
IMG_20190129_113232…. and this is the Starboard side vent box.

The cut out area is where our BBQ will be mounted as these two vent boxes will serve double duty as our outdoor Galley with sink, cutting board and storage to join the BBQ.
Arch up   downThis rendered view will help put this all into perspective with the two ER Vent boxes in red.  Mist eliminator vent grills will be on the inside surfaces to keep salt water and humidity out and inside each box is a set of baffles to direct air in and out of the ER and others to bring fresh air into the Guest Cabin and Christine’s Office.
IMG_20190129_112853The other exciting development this week was the arrival of this truckload full of ……….

………….. can you guess???
IMG_20190129_113359The busy little worker ants they are, Naval people appeared out of nowhere …..
IMG_20190129_113744…. and within minutes they had the full load moved from here ……..
IMG_20190129_114215……. to here.

Did you guess what all these bags are full of?
IMG_20190129_114256Correct!  It is all our EPDM foam insulation.  Most of this is 50mm/2” thick which covers all the interior hull plates, underneath all the deck plates and in the interior walls …….
IMG_20190131_150323….. with some 10mm / 3/8” for covering the aluminium stringers and frames so let’s show you how this all works.
IMG_20190131_131448We experimented and consulted with the manufacturer of the EPDM foam and came up with a 3 stage process. 

First the horizontal stringers are have lengths of 10mm EPDM fully wrapped around them and glued in place with a special contact cement.
IMG_20190131_150512Second, more lengths of 10mm EPDM are cut, fitted and
IMG_20190201_103445…… glued to the frames.
IMG_20190131_150447With all the stringers and frames covered the 3rd step in the overall process is to cut, fit and glue the 50mm EPDM to the aluminium surfaces.
IMG_20190202_150459Here is a small test area in the aft Port corner of the Workshop with all three steps completed between four frames and two strips on the ceiling. 
IMG_20190202_150548This is a very laborious process as there is a LOT of intricate fitting to the different shapes, sizes and openings that need to be carefully and completely covered.  It is important that the adhesive covers every bit of the aluminium and foam so there are no air bubbles trapped underneath to ensure that no moisture can get in and that there are no thermal bridges created between the aluminium components and the interior spaces and cabinetry.

You will be seeing lots more of this process as it progresses over the coming week and I can explain more about why we are going to such pains to put in this type of insulation and why we believe insulation is one of the most significant factors in making these kinds of eXtreme Passage Makers so comfortable and so efficient in both eXtremely hot and cold areas in the world.

Mert & Yigit foot to foot

Saving the best bit of progress for last here is this week’s boatload of cuteness to let you know that the Dinc twins Mert and Yiğit also continue to grow and develop eXtremely well.

I hope you are enjoying seeing this all unfold as much as we are and that you will continue to follow along with the whole process of building our just right, just for us Goldilocks boat. 

See you next week!