The Artnautica Family Continues to Grow XPM78-01 Möbius 6-11 Sept. 2021

Our lives aboard Möbius have settled into the same pattern of working our way through the list of jobs needing to be finished before Möbius is fully sea worth and ready for us to get back to crossing oceans and eXploring the salt water world we both love so much.  This work is far from “glamorous” or eXciting, just neccessary and a pattern we are accustomed to from our decades being full time live aboards and stewards of many boats before.

What IS eXtremely eXciting is the arrival of more and more members of our family of XPM style boats from the desk of our beloved Naval Architect and designer, Dennis Harjamaa who runs Artnautica Yacht Design in Auckland NZ.  So let me provide a bit of background to help put this all in context.

Finding our Goldilocks NA and Designer for XPM78-01 Möbius

Back in 2016 when Christine and I got serious about switching from sail to power and designing and building our own new “Goldilocks” just right, just for us passage maker, we spent a year searching the world for our equally Goldilocks NA.  There are a LOT of Naval Architects and boat design firms but what made our search so challenging was that we did not want to be just clients the designer worked FOR and end up with a boat design that was based on what the designer thought was best.  Instead we wanted a designer who would work WITH us in a highly collaborative way to transform the very specific visions and specifications which we knew well from all our nautical smiles at sea.  It took us almost a year and a lot of both nautical and air miles but we finally found and met up with Dennis when we had our previous boat in New Zealand and we knew right away that we had finally found our Goldilocks guy.

Winding the clock back a few years more, somewhere around 2010, after designing a lot of very successful smaller boats, Dennis set out to design the Goldilocks boat for himself and his partner Raquel to live aboard and enable them to start exploring the world by sea. 
LRC 58 render from siteWhat he came up with was the LRC58 which you see rendered here and hull #1 called “Koti” has been their full time home near Auckland since it launched in 2013. 


LRC 58 tech specs screen shotSince then FIVE more LRC58’s have launched from the Aluboot yard in the Netherlands and you can read all about them HERE on the Artnautica.EU website.
But wait!  There’s more!!!
LRC 58 photo from Artnautica web site

Not only did Dennis design the LRC58, he also built her almost single handedly!  So now you are starting to understand why Dennis was and still is to this day our Goldilocks XPM designer!

The XPM Line of Boats Begins

Christine and I found the LRC name to be too generic and overused in the boating world and so we came up with the more specific eXtreme eXploration Passage Maker or XPM title to better suit this unique style of boats and therefore Möbius became hull #1 of the new XPM78 design.

PGL sketch 58We spent almost two years working with Dennis in what quickly became a collaborative work of art and engineering and resulted in the completed 3D model and drawings that were used by Naval Yachts to build XPM78-01 Möbius.
 Möbius in IcelandThis is a relatively new style of boat which do not yet have a common name or acronym but are all designed and built for a small but growing group of like minded people with a common set of priorities and use cases.  They are most often a couple, sometimes with a child or two, who want to be able to have a floating home that can carry them across oceans and eXplore the most remote spots on the planet and do so with the highest degree of safety, comfort, efficiency and low maintenance. 
2_13Such requirements tend to determine the overall characteristics of these boats so they are long, slender and slippery all aluminium hulls that are low to the water, self righting and efficient to run with as low amount of maintenance as possible to operate.

Since designing our XPM78-01 Möbius, more and more people have been intrigued by what Dennis calls his LRC or Long Range Cruising boats and have sought him out to design a Goldilocks version of an XPM for them and that’s what brings us to this post.

Over the years as more people became aware of our work building Möbius and chronicling it all with these weekly blog posts, Christine and I have been fielding more and more requests by people wanting to know more about these XPM boats,  In spite of my Emails being even longer than my blog posts, some of these people have been brave enough to keep asking questions and receiving more and more of my novellas aka Emails as their interest grew.  In several cases this has led to them coming to meet with us for lengthy tours of Möbius, Naval Yachts and the Antalya Free Zone and as you’re about to see, in several cases this ultimately led to several signing on the dotted line with Artnautica and Naval to design and build an XPM for them.

XPM78-02 Vanguard

WhatsApp Image 2021-09-07 at 8.26.40 PMThe first are an American couple, Chris and Sebrina and their son Rhys who not only endured hundreds of pages of my Emails but they also very courageously flew over to Antalya last December and we spent several days with them aboard Möbius as she was nearing the end of her build and showing them around Antalya and Naval Yachts.  Apparently they liked what they saw as a few months later they had signed on with Artnautica and Naval to design and build what is now hull # 2 XPM78-02 Vanguard. 

These are some relatively recent renders of how hull #2 has evolved.
Vanguard rendering 4 Jan 2021You can see the XPM78 family resemblance and she is based on the same models as Möbius.  However Chris & Sebrina worked with Artnautica and Naval on some important modifications to make this the just right, just for them, XPM78.
Vanguard rendering 1 Jan 2021Keen eyed followers might notice that the Pilot House has been lengthened by about 1 from aka 1 meter which is a change that we recommended as well for all future XPM78’s.  More significantly and perhaps controversial, the Pilot House has also been raised by about the same amount to enable the area underneath to become living space that includes a 3rd cabin.
Some of the other key changes that Vanguard will have include:

  • Twin John Deer 4045 engines with double prop tunnels to keep the draft down.
  • electric hybrid propulsion by Praxis added to the propulsion from twin JD diesel engines
  • addition of a 3rd cabin
  • extending the PH as noted above to make the salon in particular more roomy.
  • raise the PH to convert what is the Basement on Möbius to all living space on Vanguard.
  • bulwarks wrapping around the side and bow decks
  • windows in the sides of the hull

Some will love those changes, others will question but all that matters is that this is what’s best for Chris, Sebrina and Rhys.

WhatsApp Image 2021-09-07 at 8.28.22 PMThere are a growing number of designs similar to these XPM’s from other companies that have appeared in the past couple of years but almost none of these have gone on to be built.  So pictures like this are a big deal IMHO!


PXL_20210505_140504218

Construction at Naval began in April and matches the way Möbius was built.  A steel frame is built on the shop floor and then the hull is built upside down on top of this.  For the curious, if you go back to posts here starting around April 2018 you can see when Möbius was at this same point and follow the construction from there if you’d like to look into the future of the building of Vanguard.
WhatsApp Image 2021-09-07 at 8.27.35 PMThis is the most recent photo I received from Chris which I think was taken a few weeks ago at the end of August.

I believe Chris and/or Naval will soon be creating a blog to cover this build and I’ll be sure to pass that on here for those interested.

XPM85-01

Artnautica LRC83 10Not to be outdone, another couple, Andrew and Lily, also from the USA have recently signed on with Artnautica and Naval to build XPM hull #3 and this one will be much larger at 85’ LOA. 
Artnautica LRC83 11Covid travel restrictions have not allowed us to meet in person yet, but Christine and I have had some video calls with Andrew and Lily and they too have been subjected to my barrage of Emails as I attempt to answer all their questions. 
WhatsApp Image 2021-09-07 at 8.29.05 PMUnfortunately as you may have heard in the news, there has also been a Covid related shortage in the world’s aluminium supply so work on both XPM78-02 and XPM85-01 has been delayed but Naval has been busy getting ready for the aluminium to arrive by building the steel support structure that XPM85 will be built upon.

Dennis and Naval are still working with Andrew to finalize the design so I don’t have much more to show you yet but will bring you updates when I get them and we could not be more eXcited for Andrew & Lily as their dreams are transformed into very real aluminium.
But wait!  There is still MORE!!

Meanwhile, in the Netherlands

lrc58-july-2017-78-1 LaunchAs if these new XPM builds were not enough eXcitement for one blog post, things have been equally as busy or more so over in the LRC world of Artnautica.  Somewhere around 2018 Dennis was in conversation with the owner of LRC58-03 Britt which launched from the Aluboot yard in July 2017
BrittRob Westermann and his wife Janet have been touring the many waterways surrounding the Netherlands and their conversations with Dennis soon resulted in Rob setting up Artnautica Europe.  Rob and I first met at the big METS marine trade show in Amsterdam back in 2018 and have gone on to become very good friends who have visited with us in Antalya several times. 
Rob is eXtremely bright and entrepreneurial and he has been a great partner with Dennis to extend and expand the LRC line of boats being built in the Netherlands as well.

Rob & Janet enjoyed their life aboard Britt so much that they decided they wanted not only more time but more boat and so began a conversation and a whole new design process that has now culminated in the LRC65 which will become the new home for them to continue to explore Europe and the world. 

FYI, LRC58-03 Britt is therefore now for sale and can find out more about that and how to contact Rob HERE.

LRC65-01 Britt II

lrc65-008-a-general-arrangementAs you can imagine, Covid restrictions are doing their best to get in the way of getting LRC65-01 off the drawing board and into the build, but Rob is tenacious and very experienced so he was able to get in an order for some aluminium just as the supply was drying up and they expect to begin construction in about a month. 
lrc65-010-a-general-arrangement-6

Dennis & Rob have created two layout versions GA 5 and GA 6 have each with different galley, settee, and helm station positions, as well as a different position of the staircase leading forward. This could be interchangeable between the two layout options.
LRC65-June-2021 - 5mmAs you can see here in this rendering of the framework of LRC65, the LRC/XPM boat similarities are much more than just skin deep. 
PGL sketch 67Here is a similar shot of Mobius’ framework.  When you peel away the outer aluminium plating, the familiar Artnautica framing signature is very clear to see.

LRC65 sketch 37There will be several propulsion options for the LRC65; twins of either Beta 75 or John Deere 4045 DTF 70 (80hp). The single-engine option will have a turbocharged four-cylinder, 130-160hp engine, likely supplied by SABB who make the CPP gearbox of choice and can therefore supply the whole driveline (Deutz, Iveco, and AGCO Sisu).

Cruise speed is 10 knots.

All the specifications for the LRC65 can be found HERE on the Artnautica.eu web site.

Phwew!!!  That was quite the tour of the XPM Family Tree! 

IMG_1581Coming around the XPM world full circle, I will leave you with this photo of the very first XPM, our beloved Möbius.


Hope you enjoyed the tour and if you have any questions or would like to consider creating your own XPM just let me know in the “Join the Discussion” box below or send me an Email to us at wayne.christine@mobius.world

-Wayne

What Moves a Boat? XPM78-01 Möbius Update Aug 30-Sept 4, 2021

The cooling trend continues with the weather here in Finike Turkey as the daytime highs drop down below 34C/93F most days this week and the forecast calls for our first sub 30C/86F high next week. 
Mobius   swimming spot labelledWe are very fortunate in that we have a huge swimming pool here at Finike Marina, aka the Mediterranean Ocean, that is just a short walk down along the sea wall from where Möbius is docked.
PXL_20210905_140154110We are able to have our nightly swims thanks to a set of stairs up over the sea wall that the Finike municipality put in several years ago. 

You can see more of our nightly swim spot in the fun video HERE which Christine put up last week of her first solo piloting of our Mavic Air 2 drone.
PXL_20210905_140239552So every evening around 7pm or so, we exchange our work clothes for our bathing suits and make the short walk down to this set of stairs up over the sea wall every evening after we stop working and swim off this landing for 15 minutes or so.
Swim shower   MöbiusWe even a fresh water shower to rinse off all the salt on our way back to the boat.

Oh!  AND we also have the AirCon working very well now for those days that are still a wee bit too warm, so we are very comfy and grateful to be here.
I am running late here getting this blog written on Sunday afternoons as usual and it has been another very busy work week getting more and more of the jobs done on Möbius but I’d like to share some details on a set of related topics which I get asked quite about very often and which seems to be surrounded by SO much confusion and misinformation; Power, Load and fuel consumption.

What moves a boat?

Seems like such a simple question, and the answer really is equally as simple and yet, in talking with other boat owners over the years, both in person and online in various forums such as Trawler Forum, I’m often surprised at some of the things I hear otherwise very savvy and smart people say when it comes to things like Horse Power, fuel consumption, propellers and other aspects of the propulsion of their or other people’s boats.  I was reminded of this again just this week by a post that Steve D’Antonio sent out in his August 2021 Newsletter “Full Throttle vs. Full Load”.  If you are not already subscribed to Steve’s newsletter I recommend it highly as a super valuable source of very thoughtful advise and info on all things boating.

In this most recent article, Steve goes over the often confused differences between full throttle and full load and more importantly he links to a much longer and well written article of his called “Wide Open Throttle” from  back in 2010 for Professional Boat magazine which I also recommend eXtremely highly if you are not already subscribed (free) as ProBoat is one of my best learning resources and I have their entire library of magazines.  

Both of these articles are must reads in my opinion if you would like to understand the relationship of HP, fuel burn and power going to your propeller.  However THE best explanation of this relatively simple set of relationships is written by Tony Athens at Seaboard Marine in his very well titled article “Propellers Move Boats, Engines Just Turn Them”.  All three of these articles are very much worth your time and I will circle back around from what they address  in a future article here to talk more about why we have a Controllable Pitch Propeller or CPP on Möbius.   It will also address why we chose to have a Gardner 6LXB turn that CPP

Once you have read these over I think that you will clearly understand what so many don’t seem to.  The major points are as follows:

  • The rated HP of any engine tells you very little about the amount of fuel it will burn or the load that engine will be running at.
  • When I am having these discussions my key point is that HP = amount of fuel burned, full stop, no other information or variables required.
  • However, to quote a much fuller explanation from Tony’s article the single best relationship to understand is “… the amount “FUEL BURNED” is the amount of “HORSEPOWER PRODUCED.” That is the COMMON DENOMINATOR, not ENGINE RPM, and NOT the actual rating of the engine. And, what makes the engine produce a given amount of horsepower is how the propeller loads the engine.”
  • Using one of the example’s Tony uses near the end of his article, if you have the same make and model of engine in two identical boats, but one is set up by the factory, to BE ABLE TO reach a maximum of 300 HP and the other boat with the same engine is set up by the factory to reach a maximum of 715HP, when these two identical boats are running side by side, their fuel consumption will be the SAME because the amount of HP that the boat requires is also the SAME.
  • Load can be very deceiving because it is based on the RATED HP of that engine and has very little to do with how long an engine will last. (assuming it is not overloaded).   As Tony outlines in his article, you can set up the same Cummins QSM11 300HP to 715HP, for the otherwise exact same engine.  So if the propeller requires 215HP to move this boat at a certain speed and set of conditions, then the load gauge on the 300HP engine would read 72% whereas the 715HP version would say the load was 30% and BOTH engines would last or have the same amount of “wear and tear”.  So contrary to very popular opinion, load % has very little to do with how long any marine engine will last.

If this does not make sense to you, or you have always been told otherwise, please do give these articles above a read and then let me know in your comments if you still think this does not make sense or is not correct.  Once we all have the same understanding of these basic components of boat propulsion and how they are related to each other, I will address one of the most asked questions I receive; why did you chose to use a CPP on your boat?

I know these more technical topics are not everyone’s cup of tea, but for those it is, I hope you enjoy the articles above and I look forward to any additional discussion or questions you have.

-Wayne

Möbius’ 24 Volt DC Charging System Trifecta XPM78-01 Möbius Update 29 Aug 2021

Sorry that I wasn’t able to write up this weekly update and get it posted on my “regular” schedule of each Sunday and I’ve kept you waiting till now but hopefully the wait will have been worth it as I take you on a deep dive into the DC charging system on Möbius.

On Sunday, Christine and I took the afternoon off to go explore some of the area around our new “home town” of Finike, which is something we should do more of I’m sure as boat and book work completely consumes us otherwise.  We have rented a little Fiat minivan for a few weeks so we wanted to take advantage of that and my super researcher partner had found a cool sounding little restaurant on a river about 20 minutes drive away from the coast here.
PXL_20210829_113825911.MPIt was a wonderful treat for us both and we spent the whole afternoon sitting at this table for two at this tiny little restaurant on the riverbank in an equally tiny little village off a side road.  You can see that I timed the shot to catch one of the kids jumping into the cool waters that the village had created with a small rock dam to slow down the flow.  We have found several of these little riverside restaurants during our years here in Turkey and this one was the Goldilocks just right, just for us being so small and remote.


Fresh roasted trout dinner with the full compliments of fresh salads, fries, Turkish baked bread and sauces plus a well chilled bottle of Merlot made for the perfect getaway afternoon for us both.  Total bill was an exorbitant USD 30 but heck, we’re worth it!

PXL_20210825_082655138We weren’t the only ones chillin’ ourselves waterside as Barney enjoys his very own pool on the aft deck where he can survey his Kingdom while staying well hydrated.

Yes, that’s the bow of our Tender “Mobli” which when on deck serves double duty in providing the shade for Barney’s pool.

Möbius’ Charging System Trifecta

XPM Electrical System v5Back in September 2019 I wrote the first Tech Talk to outline the overall design we came up with for the Electrical System and this is an updated version of the schematic I created of the overall system.

As per this week’s title I believe that we have put together the perfect trifecta of components to make our Goldilocks 24 Volt charging system consisting of;

FireFly House battery bank24 x FireFly Carbon Foam 4v cells

Just 10 of them shown here and these have been well covered in many previous posts. 


Electrodyne pair wo junction boxes2 x  Electrodyne 250A @ 24V AC PowerHead E250-24 alternators with remote rectifiers mounted out in the Workshop (see photo below)

PXL_20210830_1124116762 x WakeSpeed 500 Smart Regulators with the 2 red remote Electrodyne rectifiers mounted alongside

I have written several articles in the past as these components were being installed and if you’d like more details on that here are links to some of those past postings:

NOTE:  Just to be clear for anyone who might wonder, Christine and I have purchased all of the equipment I’m discussing here and none of this has been sponsored or otherwise paid for.  indeed this is true for ALL of the equipment on Möbius and covered in this blog.  We are simply BIG fans of companies who produce products that really work in our eXtremely real world and especially the people at these companies who stand behind their products from the beginning of our work with them to design systems, install them and all the way through to their support as we move into commissioning and putting all these systems to work. 

So we are delighted to feature such products and the people behind them here on the Möbius.World blog.

Meet Big Red #1 & #2

As I wrote in those past posts, I’d known Electrodyne alternators since I was working as a HD construction mechanic in my youth and Electrodyne alternators were the ultimate choice for large construction and mining diggers, railroads, trucks, busses, emergency vehicles where they often ran 24/7 for weeks or months.  They are literally built like tanks and each one weighs 40kg/90 lbs!

Electrodyne Factory 8I had initially worked with Pete Zinck until he retired in 2018 and turned things over to his Production Manager Dale Gould and who could not have been more helpful and responsive to my many Emails and requests.

As you can see Dale is also a very hands on guy!  Here he is making the final checks and tightening the remaining nuts on finished alternators awaiting packaging.

Dale continues to be super supportive as I commission the whole charging system on Möbius and I can not recommend Electrodyne and Dale highly enough.


Electrodyne with labelWhat we ended up choosing are two identical Electrodyne E250-24 models which are de-rated down to 250Amps @ 27.5V @ 3750RPM which would give each one a maximum output of almost 7kW (6.875) for a combined output of almost 14kW.   As I covered in last week’s posting about the drive systems for these massive alternators, I chose some ratios for the pulleys such that their max speed will be about 3200-3400 RPM for even longer life. 

These “PowerHead AC alternators” have several unique characteristics that made them just right for me and Möbius:

  • Brushless so no brush springs or brushes to wear out
  • One moving part (rotor)
  • Everything other than the rotor is external; No built in regulators, No built in rectifiers. 

Why go to such extremes?   In a work; HEAT, which is the largest factor in shortening an alternators output and lifespan. Rectifiers can produce more than half the total heat within an alternator so by removing these and going with industrial grade 3 phase bridge rectifiers I can reduce the internal head of the alternator by more than half AND control the heat of the rectifier bridges outside the ER and with their own fans.  

With only one moving part, the spinning rotor so MUCH better airflow through the alternator stator windings and rotor.  The Goldilocks alternator for an XPM; consistent high output with low heat and low maintenance.

Electrodynes with me holding junction boxEach PowerHead is “double headed” housing two separate AC Alternators inside, one on each end.  Having two of these Electrodyne units means we have 4 alternators in total.

With no rectifier or regulator built into them, each PowerHead only puts out AC current, everything else to convert this AC current to DC is external. 

As you can see in these photos, there are six large cables to carry the AC output out of the Engine Room and over to ……
PXL_20210830_112357375…… these two red external rectifiers which are mounted outside the Engine Room under one of my AL Workbench tops with thermostatically controlled fans to ensure they are always running nice and cool and at maximum efficiency.   All the heat Mr. Gee generates stays in the Engine Room which is why I designed the ER to be just that; and ENGINE (only) Room.

Q&A with Dale Gould from Electrodyne:

**  Feel free to skip to the end of this section if you are not interested in a deep dive into the inner workings of  how these Electrodyne alternators work.

For those of you interested in more details on the unique way these Electrodyne PowerHeads work, I asked Dale a series of questions and he kindly answered them as follows.  I’ve added some photos I took when I was taking these alternators apart and painting them, to help illustrate these Q&A.

** Before you ask, Yes, of course I took these Electrodyne alternators apart!  When I don’t understand how something works or I am otherwise curious, this is what I do.

PXL_20201124_134037297Wayne’s Q:     In working with the two Electrodyne E250-24 PowerHead alternators you built for us, I’ve noticed that they are built quite differently that any other alternators I’ve worked on.  Can you tell me a bit more about how you build these and why?


PXL_20201124_134411083Dales A:     When looking at the inside of an E250-24 you will notice that the Electrodyne’s are built completely opposite of a normal alternator. The rotor spins around a stationary stator rather than the rotor being inside the stator (Claw tooth design). The reason we do this is to achieve more power. By having a larger stator inside the unit that can hold larger sized wire we can achieve higher outputs. We have fine-tuned the size of the magnet wire to the amount of turns per coil to achieve certain outputs at various voltages. We also use an individual lamination stack made up of either 54 or 64 laminations depending on unit and voltage. This helps us reduce eddy currents and allows us to dissipate heat more efficiently. This method is also used in our rotor lamination stacks.
PXL_20201124_134032959Wayne’s Q:     I understand that these are permanent magnet or PMA alternators so can you tell me why there are still Field Coils and what their role is?
PXL_20201124_135938081Dales A:    The field coil is essential to all units as it works in tandem with the stator to achieve the voltages, output, and current desired. Each field coil has also had extensive testing with different turns of wire at different thicknesses for the highest performance. Even though the rotor has magnets in it a field coil is still necessary.
The field coil is what supplies the magnetic field in the alternator. On certain alternator applications such as yours, Electrodyne will add permanent magnets to the rotors to aid in additional magnetism to achieve higher outputs and a lower turn on speed.

PXL_20201205_072756095Wayne’s Q:     Most alternators, even high output ones I’ve used in the past, their cases are typically made from aluminium and are much smaller and lighter than these beautiful  cast iron beasts you make.  Can you explain the reasoning behind this?
PXL_20201123_134038473Dale’s A:     The housing we use is cast out of ductile iron for two reasons. Extreme durability and magnetization. When the unit is first powered on and magnets are introduced to the rotor, we magnetize the housing. This also contributes to higher outputs as the whole housing now acts as a magnet itself. Electrodyne uses an insulated grounding method for its alternators so nothing goes to ground unless specified by the customer. Having an insulated ground system allows for the Electrodyne’s to be either negatively or positively grounded.

Electrodyne AC cables into External rectiferWayne’s Q;     I chose to go with your Electrodyne alternators largely because you not only removed the regulators but the rectifiers as well so I can mount these as separate units outside of the alternator cases and outside the Engine Room.  The rectifiers like this one here also have their own thermostatically controlled fans.  This dramatically reduces the amount of heat being generated inside the alternator cases but there is still some, so how do you keep these PowerHeads running even cooler and for so much longer than other makes?

Electrodyne Factory 7Dale’s A:     The rotors of an Electrodyne alternator act as two large fans. There are holes plotted along the casting of the housing that act as breathers.

Photo Dale provide from the Electrodyne factory showing the rotors being machined.


PXL_20201124_134039908The fan spinning will pull air from outside and cool the two major components of the alternator (stator & field coil), simultaneously ejecting that air out and keeping the inside free of excess heat buildup.

Another way the alternators deal with heat is by switching the field on and off (pulsing the field). This turns the field of the alternator off to allow free spin when a load is not required. The rotors are also bi-directional. They will cool the unit with either directional rotation an engine uses.
PXL_20210830_112422607Finally, on a remote rectifier system like yours, we remove the diodes from the top of the alternator and give them their very own fan cooled housing. The E-2281 is mounted with a fan that keeps the diodes cool while under load. The diodes used on Electrodyne’s are extremely important and need to be able to withstand constant abuse. The diodes act as a check valve for electricity, turning the AC current the alternator produces and eliminates the back and forth alternating current to a straight-line direct current. Our diodes are rated to a 900-ampere capacity and offer a high load dump capacity as well. Ensuring that electronic equipment such as regulators are not damaged when the unit is powered down.
PXL_20201123_134036270Wayne’s Q:   As I looked more closely I can see that these PowerHeads are not just heavy in weight they are truly Heavy Duty as well.  With our focus on Maintenance (Lack thereof) and longevity this was another big factor in my choosing to go with Electrodyne alternators so can you give me some details of how you have designed and built these alternators to be so long lasting?
PXL_20201124_115759016Dale’s A:     The Mechanical parts Electrodyne uses are made for longevity. The bearings used are class 3 ball bearings and needle bearings that have a 20,000-hour rated life. The reason we use such long lasting mechanical components is for duration of life for the alternator. When an Electrodyne is purchased peace of mind should go along with it. Minimal failure rates are key to the Electrodyne advantage. With a brushless design we can eliminate parts from wearing over time.
Thanks Dale!!!

Mounting the Red Monsters:

If you read last week’s post you know all the details of how I’ve designed and mounted each Electrodyne to be driven differently so here is a quick summary.


PXL_20201222_153045213Big Red # 1 is up top, resting on the large flat mounting surface cast into all Gardner 6LXB Crankcases and then driven by a cogged tooth rubber belt being driven by the crankshaft pulley.  This drive setup has a 2.15:1 ratio, meaning that the alternator rotates at 2.15 times the RPM of Mr. Gee’s crankshaft.

Electrodyne-_2-jack-shaft-labelledBig Red # 2 is down lower where it is bolted directly to the side of the AL crankcase to align with the gear driven PTO or Power Take Off on the bottom front corner of all 6LXB engines.  I modified a jack shaft to connect the two very solidly together as you can see here.  The drive ratio for this alternator is fixed by the internal gears driving the PTO shaft at 1.80:1 so this alternator #2 will spin a bit slower than #1.

No Generator = Best Generator?

I am often asked how Möbius can be completely self sufficient electrically without having at least one if not two stand alone diesel generators as would be typical of most other passage making boats and trawlers.  First part of the answer is that the 4.48kWh from our 14 solar panels is enough to keep our 43.2kWh battery bank fully charged most days and the second part is that if not, the combined output of these two Electrodyne alternators are able to add up to 12kWh of their own. 

SCEM boxDesigning our charging system this way eliminates the need for a separate generator and aligns perfectly with our SCEM priorities of Safety/Comfort/Efficiency/Maintenance to give us the best generator of all; none!

To be fair and technically correct I guess it can be said that we do in fact have a generator onboard, and a 12kW one at that!  Just not in the traditional sense nor with all the traditional cost, noise and maintenance.

Electrodyne Output Details:

I’ve received quite a few questions about the numbers behind our charging system so let me provide the following info to help answer these:
Electrodyne E250 24 Performance GraphsHere is a scan of the graphed results of the test runs that Dale did at Electrodyne of our E250-24 PowerHead alternators.

(Click to enlarge this or any other photo)

Using this graph I can see the output of each alternator when they are spinning at any RPM as well as how much power they need Mr. Gee to provide to do so.

Electrodyne RPM   Output chartUsing those numbers, I have put together this simple spreadsheet to show the output of each Electrodyne alternator when Mr. Gee is spinning them at different RPM’s and the combined total output at the bottom.
For example, when Mr. Gee is running at 1000 RPM, we have a total output of 363 Amps @ 24 Volts or 8.7kWatts and at our typical cruising speeds he is running at about 1500 RPM and there is up to 478 Amps/11.5kW available from the two Electrodyne alternators.  Hence, anytime Mr. Gee is running, we have more charging power than we would ever need whether we are in tropical climates or the polar regions.

The Secret Sauce:  WakeSpeed 500

I very purposefully refer to our charging setup on Möbius as a SYSTEM and each of the three components of our system are important and neccessary members of the team. 

Wakespeed[1]But what I think has really turned this into an eXtremely good system is the “brains” of the system; our two every “smart” WakeSpeed 500 Regulators.  It is not at all hyperbolic to call these regulators “advanced” as they do on their cover and let me explain a bit more about why these are the true Goldilocks factor for our charging system on Möbius.
And don’t take just my word for how truly revolutionary and smart these WakeSpeed regulators are!  Here are some reactions from others MUCH smarter and more qualified than me as to how well these worked when they installed WS500’s on their boats:

“The notion of using current, as well as voltage, to regulate charging has always been the holy
grail for intelligent battery charging. With WakeSpeed Offshore’s new WS500 Advanced alternator
regulator, we now have that ability.”

Rod Collins — from www.marinehowto.com


“The WS500 also has a bunch of whiz bang features, but the cool thing is all most of us have to
do is install a shunt (if not already present) and replace our stupid regulators with this smart one
— and the even cooler part is that because this regulator is designed right — measures and
acts on net charge current — we don’t need to spend hours reprogramming it to get around its
fundamental stupidity.”

John Harries — from www.morganscloud.com

Just as with Dale at Electrodyne it was the people more so than the electrons that mattered most.  From the beginning, I was able to work directly with the two brains behind the smarts of WakeSpeed, Al Thomason and Rick Jones who created this amazing product.  Al and Rick are both veterans of the marine charging world and are founders and inventors of WakeSpeed.  Even better, Dale, Al and Rick all teamed up and worked together with me to do more testing on the combination of Electrodyne alternators being controlled by WakeSpeed 500 regulators charging FireFly Carbon Foam batteries!  Does not get any better than that and I can’t begin to thank these guys enough for putting up with my incessant Emails and questions.  Thanks guys!

The key features that make these WS500 regulators such a Goldilocks fit in our charging system are that they monitor and use a combination of system voltage, current in/out, alternator and battery temperature and alternator RPM to continuously adjust the Electrodyne’s to be the Goldilocks output for the FireFly Carbon Foam batteries at all times.  Until WakeSpeed came along all our previous regulators could only use voltage to monitor and adjust the output of the alternators whereas the true indicator of what’s going on battery charge wise is the current (amps) going in/out of the batteries. 

It was also not lost on me when I first started researching them several years ago, that WakeSpeed had already created custom profiles for FireFly Carbon Foam batteries and this was one of the examples that told me that these Carbon Foam batteries met my Tried & True test that I require for all our critical systems on Möbius or any XPM.

PXL_20210830_112431859The other Goldilocks factor for our installation is that both my WS500 regulators can be “daisy chained” to work together and automagically synchronize the outputs of both Electrodyne’s by using both WS500’s to perfectly meet the needs of our FireFly house bank and everyone plays nicely together.

Sound difficult?  It normally would be and would require additional relays or switching devices, but not with the WS500’s.  All I do is plug a standard ethernet cable (white cable in this photo) into the RJ45 jacks in each WS500 and they become one big happy charging family.


Without going into too much detail here as there is lots available elsewhere that I will link to in a moment, it is the use of current (amps) going in/out of the batteries that adds the previously missing secret sauce to ideally optimized charging systems.  Prior to these WakeSpeed 500 units, regulators were correctly called Voltage Regulators because that is what they monitored to control the charging output of an alternator.  This obviously works because generators and alternators have been using voltage regulators for over 100 years to do their job.  BUT, voltage by itself is not a very accurate way of determining the state of a battery and what we really care about is the amps flowing in/out of a battery to provide a truly accurate and just in time determination of what the batteries need from the alternator which ranges from everything they’ve got to nothing at all.

Some other great people have done a MUCH better job than I ever could at not only explaining their perspective on WS 500 regulators, they do so having installed these on their and other boats so they are speaking based on my favorite kind of knowledge; eXperiential.  Here are links to these great resources so you can learn more from these others:

WakeSpeed Setup:  Have it Your Way

Wakespeed-WS-500-circuit-board with DIP switchesThese WakeSpeed 500’s not only have the electronic smarts to do all of this, they have been put together in a package that I think is just brilliant.  It can be as simple or as complex as you’d like to configure these regulators.  For example, if you want to KISS the setup to your system, there are a set of 8 DIP switches inside each WS500 case and you just flip these to a pattern of On/Off and you’re done.
WakeSpeed Quick Start GuideRick and Al and their crew at WakeSpeed also get a gold star from me for their documentation.  NOT an easy award to get nor one that I am able to hand out very often I can assure you.  For example, how well done is this Quick Start card?!  Clear, concise, colour coded and shows you everything you need to know to connect and configure on one page!  Connect the wires, set the DIP switches once and you can leave it at that for most installations.
Adding to this already impressive feature list, WS500 regulators also provide me with these very valuable benefits that would otherwise not be possible or not easily obtained:

  • Adaptive Idle Technology™ which allows me to set the WS500 to control alternator loads based on
    engine RPM.  We can use this at both ends of the spectrum; when getting underway, doing close quarter manoeuvring and such we would typically have Mr. Gee at lower RPM’s and want all of his available power for moving the boat and don’t want or need any loads from the alternators.  But if/when we want to add the output of the Electrodyne’s to our solar charging when at anchor, we can turn on our “Gardner Generator” by dialing up the loads on Mr. Gee at lower RPM’s to produce high outputs from the alternators to charge the batteries faster.  This keeps both the batteries and Mr. Gee very happy.

  • Zero Output Technology™ enables the regulator to limit output to
    loads  when batteries require discontinued charging.  This is particularly valuable for Lithium battery installations but this will be very handy with our large solar outputs when we don’t want or need any output from the Electrodyne’s when we are on passages.

More Goldilocks Gold

At the opposite end of the KISS spectrum, for those of us who might want to “geek out” more and really customize our charging system to be a truly Goldilocks setup, the WS500 regulators have more than 100 parameters that can all be adjusted and tweaked to get that just right, just for your boat’s charging setup.  While this an get you “into the weeks” of minute details of charging systems there are several tools and utilities to make these adjustments relatively easy and quick to do.  WakeSpeed is also to be commended for doing everything with open standards and being equally open themselves and we are already seeing a rapid growth in the number of companies making batteries, alternators and other components who are building custom profiles with all the specific settings for the WS500 to use.  This method of having profiles, which are just small text files, that can be freely shared and easily uploaded into any WS500 via SD cards, USB cables, WiFi interfaces, etc. makes these WakeSpeed regulators a truly Goldilocks solution.  You can see a list of some of these profiles and other technical documents HERE on the WakeSpeed web site.

Real World Data Coming Soon

I am still finishing up the final wiring of the WakeSpeed 500’s and the Electrodyne alternators so I have not been able to run this charging system and gather the real world data of all this at work; yet!  But do stay tuned as I get this and the other critical boat jobs finished so we can take Möbius out on more trial runs and start to log all the data from this charging system and put some real data behind all this work to design and build our Goldilocks charging system.  I’m waiting on some parts for Mr. Gee to arrive from the UK and complete a few other jobs that are keeping us tied to the dock here in Finike but I’m hopeful that we will be able to head out by the end of September and as soon as we do I’ll be posting updates for you that provide the proof of how all our systems are performing, including the charging system you now know all about.

Hope it was worth the wait of an extra few days for this week’s Möbius Update and that you found this latest posting to be of interest and value.  Either way, I would be most appreciative of any and all questions and comments you can provide in the “Join the Discussion” box below. 

Your Feedback Wanted:  More Q&A type content and more Video?

On a related note, I’ve received some good suggestions that I start doing some Question & Answer sessions in some of these blog posts so if you have some questions that you would like to see me cover in a Q&A section, please type those into the box below and I will start to gather them together and post some answers to them in future blog posts.

I have also been receiving more requests to also start creating more video based content to cover the boat now that it is more finished and to consider including some Q&A sessions in those videos so let me know your thoughts on that and if there is enough interest, Christine and I will do our best to start creating more video content to post here and on YouTube.

But Wait!!!  There’s more!  Speaking of video content, if you have not already seen it, be sure to check out the great little video segment “The Drone Report” which Christine just published last week based on her first solo test piloting of our DJI Mavic Mini 2 drone.  She’s a fabulous story teller in any medium and you can see that clearly in the suspenseful context of her first drone flight.  You will also get a great hi-rez aerial tour of the Finike Marina and Möbius so it will be well worth a few minutes of your time.  CLICK HERE and enjoy!

-Wayne

Drive by Belting XPM78-01 Möbius 16-20 Aug 2021

Another hot and busy week onboard the Good Ship Möbius here in the Finike marina as we continue to work on the seemingly endless ToDo list of jobs we need to complete to get Möbius fully ship shape to the degree that we can be confident to go to sea on her.  Weather here continues to be wonderful although the daytime temps have been creeping up to the mid 30’s (mid 90’s for those who are metric challenged) but we have the AirCon working very well now and use that to cool down Christine’s office during the daytime, the SuperSalon for dinners and our Master Cabin just before we head off to bed.  The “eXcessive” EPDM insulation we installed throughout the boat is really paying great dividends now as it keeps the heat out and the cooled down temps in so the loads on our AirCon chiller system are minimized.

This great weather, which is normal for us in this part of Turkey, also inspired Captain Christine to take to the air as she started to log more hours with our DJI Mavic Air 2 drone.  We’ve had it for quite a while but have both been so busy with boat work that we just have not had the time to fly it and become familiar with it.  Christine will put together some videos she took with it and post these a bit later for you to enjoy and I can give you this aerial view of Möbius as a teaser.

RemoteMediaFile_6553610_0_2021_08_18_10_49_34This is where we are tied up at Finike Marina and will give you a different perspective on what Möbius looks like from above.  Easy to see the 14 solar panels from this viewpoint.
Mobius @ FinikeFlying a bit further away to give you this view looking back at Möbius to help orient you as to where we are within the marina.  You can Click to enlarge this or any other photo.
Mobius @ Finike with swim spotThis pano shot from a bit further out will give you a better sense of our surroundings and where we go for our evening swim after quitting work every day.

Compressor Installed

You may recall that back in June we drove up to a big hardware store north of us to pick up a new air compressor for the Workshop and after testing it out and thinking over the best location, I got around to permanently mounting it this week.

PXL_20210804_101841556Reminding you that this is a WORK shop, so a bit messy, but you can see the white Kuletas compressor mounted underneath the Aft end of my Port/Left side workbench.

This is one of the newer types of compressors that has two motors each with two compressors so four compressors all together.  This enables each one to be smaller and run at lower RPM’s and run eXtremely quietly!  I can hear it come on when I’m in the workshop but it doesn’t interrupt a conversation and you can’t hear it at all outside of the workshop.



This air compressor is a super handy bit of kit to have and in addition to using it to power some pneumatic tools, clean tight passages out and blow up inflatable kayaks and the like, we use this to provide air to breathe using our Hookah or Snuba gear to work underneath or dive down to about 20m/65ft up to 100 feet around the boat.


PXL_20210804_101828297It was definately a shoehorned fit with less than 1cm to clear at the top but this location keeps the compressor out of the way, easy to service and uses an otherwise not so usable wedge shaped space. 
PXL_20210819_115224928And of course we continue to have some “infant mortality” jobs on the list such as when this seam in our brand new sand filter burst and started spraying seawater all over the Workshop.

While I hunt down a newer and better version I have just bypassed this for now and run the seawater supply to our Delfin 200L/hr watermaker through just our primary and secondary sediment filters for now.  These “media” or sand filters are most commonly used for swimming pools so many of you will recognize this.  However they are the secret weapon for dramatically reducing the maintenance of a watermaker by filtering out almost everything down to about 5 microns prior to going to the two sediment filters.  We would normally need to clean those filters every 10 hours of use and replace them every month or so whereas with the media filter in front, the sediment filters last for over a year.

Belting Up!

What I will do for the rest of this posting is go through the belt drive system I designed and built to power the seawater pump and Electrodyne alternator mounted on the front of Mr. Gee.  I’ve been reminded by several of you that I promised to do this many months ago so my thanks for your patience in waiting until now.  Hope the wait will have been worth it.

The Problem:

To put this all in context, I had a relatively large seawater pump and two  very large alternators that I needed to mount on Mr. Gee our Gardner 6XB and then drive them both from his crankshaft. 

The seawater pump weighs about 7kg/15lbs and each of the Electrodyne 250A @ 24V alternators weigh 40kg/88lbs so the mounting system needs to be eXtremely strong and solid.  Both the pump and the alternator require a good bit of power to drive them so the drive system needed to be equally as tough and to be up for this task of years of trouble free service.

Jabsco 6400 sea water pumpI won’t go into much detail on this but the seawater pump pulls seawater direct from the sea chest in the Engine Room and then pumps this water through three  heat exchangers/coolers, one to cool engine oil, one to cool the engine’s water/antifreeze coolant and one to cool the Nogva gearbox oil before it finally and perhaps most importantly gets sprayed into the exhaust elbow to cool down the exhaust gas and then exit out of the boat. 
If this pump fails for any reason, the engine would overheat quickly and cause some extreme damage.  Both of these bits of kit are therefore very critical to keeping the boat running, the seawater pump in particular so I needed to come up with a design that would be as bullet proof as possible. 

PXL_20201205_072804595

There are two of these big red Electrodyne brutes which have a de-rated output of 250A @ 24V and each one weighs in at 40kg/88lbs and can take up to 20HP to drive at maximum output so their mounting and driving systems have to be equally as eXtreme.

However this essentially gives us the equivalent of a 12kW “generator” whenever Mr. Gee is running so these ensure that we never have any shortage of amps to keep our batteries fully charged and power all our electrical systems whenever we are underway.

Of course we are at anchor much more than we are underway so our 4.4kWp solar array keeps the batteries fully charged the majority of the time.

But how to mount them and drive them was the big question?


Direct PTO Mounting for Electrodyne #1

Electrodyne #2 jack shaft labelledMounting one of the #1 Electrodyne alternator was relatively easy as Gardner LXB engines have a dedicated PTO driven system for driving one alternator.  I had a short jack shaft in my spare parts that I was able to machine some adaptors for that connect the end of the jack shaft to the PTO output and the input shaft of the Electrodyne.
Electrodyne mount on side of Mr. GeeThen I was able to machine some other adaptors for these ribs where the alternator body bolts directly to the side of the Gardner crankcase.
PXL_20201210_143406727Using this Black metal band strap to hold it all together.  KISS and eXtremely strong, what’s not to like?

As you can see this was quite the shoehorned fit but was relatively straightforward to do compared to coming up with a way of mounting the second Electrodyne.

Mounting Big Red #2

PXL_20201222_152939154Physically mounting the second alternator was actually not too difficult thanks to the nice large flat mounting pad that the Gardner 6LXB’s have on their front Left corner.  This was originally used to mount things such as air compressors on the automotive version of LXB’s used in trucks or to mount water pumps on the marine versions.  I had another place in mind for the seawater pump so I used this mounting pad for the second Electrodyne instead.
PXL_20201222_152230392Pretty straight forward, I machined two 25mm thick AL plates and drilled them to match the spacing of the four threaded holes that were already in the mounting pad.

Then I machined and drilled the riser for the through bolt on the bottom of the Electrodyne and welded this all together.
PXL_20201222_153045213This created a super solid mounting system for this second Electrodyne.  Then I fabricated a SS bar that connects to the red tab you see just in front of my knuckles here, which holds the alternator in its final position and it was now fully mounted.

But how to drive this second Electrodyne AND the sea water pump was the big question!

Mounting the Jabsco 6400 Series Sea Water Pump

PXL_20210105_112942175Having used the Left side mounting pad on the Gardner for Big Red #2 I now needed to come up with an equally robust mount for the Jabsco seawater pump.

As you can see the pump has a simple flat mounting pad on the bottom with four bolt holes to fasten it down and wanting to KISS (Keep It Simple & Safe) I decided to go with an equally simple flat bar of 25mm thick AL which I could quite easily mount vertically over on the Right side of Mr. Gee.
PXL_20210105_114203931Didn’t take me long to fabricate this mounting bar, bolt the Jabsco pump to it and create some simple mounts for this bar to bolt onto the front right side of Mr. Gee.

As with the Electrodyne alternators, the mounting part of this puzzle was relatively easy, now on to the bigger challenge of driving both the water pump and the alternator.

Designing the Drive System

PXL_20201122_095015832I spent a LOT of time sketching out ideas on my favorite medium; old cardboard boxes!  I would sketch up very rough ideas of every possible drive system I could imagine and pulled lots of dimensions off of Mr. Gee, the Electrodyne and the Jabsco sea water pump as I refined the design.
PXL_20201122_095059641As my idea took shape I started searching for the components I would need for the actual drive components such as the pulleys for the belt and what their requirements were for power, RPM, etc..
triple V belt pulley setupI knew this was going to be a rubber belt drive system but traditional V-belts were just not up for the job even if I used two or three of them and they tend to slip quite easily if the belt tension is not just right and very tight.  They also require very close alignment or else they start to wear and through black rubber dust all over the engine room. 

Ask me how I know all this?!!
V belt pulley spectrumFor a long while I thought I was going to use a multi V serpentine belt drive setup,  As per this nice lineup of different V belt types of pulleys, you can see that these multi rib belts and pulleys are able to handle much bigger loads and are more durable.  These are used on millions of cars and trucks around the world to drive their alternators, water pumps, etc. so they are well proven.
Serpentine multi V pulleyBetter yet, I already had two of these as they came with the Electrodyne alternators I already had on hand.  You can see one inside the white rectangle on the left.
However, this still  left me with having to custom build a multi V groove pulley to drive all this off of the front end of Mr. Gee’s crankshaft and one to mount on the keyed shaft of the Jabsco water pump.  Not a big deal in and of itself, BUT if I was going to have to build custom pulleys, why not go for an even better belt drive system?

Good – Better – Best

Timing chain on a gears from a car engineTraditional V belt drives are good and serpentine multi groove V belts are better but cogged belts are THE best when it comes to driving high power shafts.  My Harley Davidson motorcycles used these instead of chain drives so I was very familiar with them and how well they worked.


PXL_20201202_143319425Many of you might know of these and refer to them as “timing belts” as they are used in millions of gas and diesel engines in cars, trucks, busses and boats around the world to very accurately drive the camshaft in those engines.  In that job they are required to have zero “slip” or else the timing of the valves opening and closing won’t work and they need to be eXtremely long lasting as replacing them can be very expensive due to all the labour required to remove and replace them on most engines.



Once I got onto that line of thinking the choice was simple.  Amongst other benefits these cogged belts gave me the following benefits:

  • Tried and True having been used for decades in millions if not billions of exiting engines
  • Readily available to buy new ones around the world if ever needed. (I of course have two spare on hand already)
  • Zero slip = zero belt dust = super accurate tachometer sensing on the alternator
  • fast, easy, tool-less belt changing
  • automatic tensioning with readily available spring loaded tensioners used in those millions of other engines
  • low axial (sideways) loads on the bearings of the alternator and water pump which in my experience is the #1 cause of failure.
  • Dead quiet operation; no belt squealing or squeaking

As you can see, this decision was easy, now on to designing a way to make this all work and find the cogged belt drive pulleys I would need to buy or make.

McMaster-Carr to the Rescue!

McMaster-Carr Purchase Order 1124WAYNE screen shotWhere do you go when you have these kinds of needs for mechanical parts?? THE best source I know of, which also happens to have one of THE best designed web sites I’ve ever used; McMaster-Carr.

Within seconds, I got to this page that had eXactly what I needed.
PXL_20201222_120936154A full range of these beautifully machined cogged belt pulleys.  Took me a few more hours playing around with different sizes for the three pulleys I needed to get the RPM just right for the outputs of the water pump and the alternator;

*  one large 142mm pitch diameter for the main drive off the Crankshaft,

*  one medium size 142mm pitch diameter to drive the Jabsco pump at its sweet spot of output when Mr. Gee is at 1400 RPM cruising speed

*  and one smaller 66 Pitch diameter pulley to drive the Electrodyne at its Goldilocks RPM.

PXL_20201222_120831621In addition to the three pulleys;   I also ordered the just right sized cog belts made by Gates.  Only one belt is needed but I ordered 3 so I have two for spares in the unlikely event that one belt breaks at some point.
PXL_20201222_121051256The real Pièce de résistance though came when I happened to notice down at the very bottom of the McMaster-Carr page you see up above, these “quick disconnect bushings”. 

Took me a few minutes to realize just how ingenious this design was and the short story is that the smaller diameter of the quick disconnect part in my hand has a slight taper to it which fits into the matching inner hole of the cogged pulleys.
PXL_20201222_121734933This allows the Quick Connect to slide all the way inside the cogged belt pully and you’ll notice that these Quick Connects are slit on one side opposite the keyway.
PXL_20201222_122050571Holding the two parts together you tighten down the three bolts which forces the tapered QC to expand and jam itself tightly onto both the keyed shaft and the outer cogged pulley. 

Brilliant!
You will be forgiven for not sharing my eXcitement but for me this mounting system to attach the cogged belt pulleys to just about any size of keyed shaft was was like a gift from the mechanical gods.  I quickly added three to my order and it was on its way to me.

Putting All the Puzzle Pieces Together

Cogged Belt Pulley Fusion screenshotI now had all the pieces for this fun puzzle but still had to design it all up so that it could be installed on Mr. Gee.  So I turned to my favorite 3D modeller, Autodesk’s Fusion 360 and was able to convert all my cardboard sketches into 3D models of each of the pieces and then accurately position them.
Cogged Belt pulleys with crank chain outline Fusion screenshotMcMaster-Carr provides 3D model files for everything they sell so I could quickly download the three pulleys and three Quick Connect fittings.  Took a bit longer to create the 3D models for the Jabsco pump and the Gardner parts surrounding the crankshaft but with those on my screen I could then try out different positions within the constraints I had from Mr. Gee. 

This was additionally challenged by the fact that I had also designed a custom version of the Gardner chain drive hand starter system which is the black line diagram you see overlaid here.
Cogged Belt Pulley closeup crank area Fusion screenshotThings were particularly “interesting” and close fitting down around the crankshaft where I needed to fit the red chainwheel for the hand starting chain and then come up with the Blue AL adaptor for it to spin on which in turn would be just the right spacing for the cogged belt pulley mounted on the custom Olive Green adaptor to attach the cogged pulley to the crankshaft.
PXL_20210127_110604783As you may have figured out by now I don’t throw ANYTHING away and so I had kept the original 4 V belt pulley that came with Mr. Gee, even though it had a large piece of it broken away.  But this gave me the center piece that was already machined to just right fit on the keyed end of Mr. Gee’s crankshaft so I cut it out with a plasma gun and used it ….
PXL_20210127_111809776….. to quickly machine it into this part which is the Olive Green part in the 3D model above.
PXL_20210228_094938203After making a few more parts, I could now dry assemble everything to see how well my 3D modeling transformed into the real world on the front of Mr. Gee.
PXL_20210127_134716593

Now to test how the belt fit and if all the pulley’s aligned with each other in all three planes so the belt would run true and free with no binding or chafing.

Worked out great!

BUT, there was still one critical part missing. 

Can you figure out what that missing part is?
PXL_20210111_132611884Correct!  I need to add in that spring loaded automatic belt tensioner! 

To mount this onto the front of Mr. Gee in just the right fore/aft position so that the black idler pulley rides exactly in the center of the rubber cogged belt, I needed to space it out about 38mm so I quickly used by drill press/milling machine to build this solid AL spacer.
PXL_20210107_082102048Next I made up a template for the 10mm thick AL plate that this would mount onto.
PXL_20210127_152247073Like this.
PXL_20210127_153448240Bolted that to the Gardner cast AL support bracket supporting the cast AL cooling water holding tank, held the spring loaded tension wheel out of the way while I slid the cogged belt into lace and released the tensioner.

Et Voila!  It all came together and works like a charm.
PXL_20210208_153342168Final piece of this multipart puzzle was to add in the chain drive hand crank system to make sure all the many players in this very busy front end all played nice together.
PXL_20210208_153614218You can see just how tight some of these clearances were in all this but it worked out just as I had modelled it, all the belt pulleys and chain wheels aligned with each other so they were all happy and it has been running like a charm for the past few months now.

Whew!  Sure glad I was finally able to put this all together for you and for those who were brave enough and preserved to get to the end of this long and winding explanation.  Congrats to all of you who did and for the smart ones who just skipped to the end.

I’ll leave you with one parting shot from Christine’s recent photo shot with the drone.  It is a bit distorted with such a wide angle but this is looking across the entrance to the marina where Möbius is a bit left of center along that stone breakwater.

IMG_1708

Thanks for joining me here again and don’t forget to add your comments and questions in the “Join the Discussion” box below.

-Wayne

How & Why We Make Our Decisions Part 2 XPM78-01 Möbius 9-14 Aug, 2021

Last week in the post called How & Why do we make all our Decisions on Designing, Building and outfitting XPM78-01 Möbius? I covered how we developed and use our set of four founding or first principles to base all our decisions upon.  We refer to these four pillars as SCEM which stands for Safety, Comfort, Efficiency and Maintenance (lack of).

SCEM boxWe don’t use SCEM as filters per se, we use them to keep us on track, keep our priorities straight, by reminding us of what our fundamental values are for this boat.  When doing our due diligence and research on some potential piece of equipment It is all too easy to get attracted or distracted by things like cool features or just the sheer number of choices and so as we go through our decision making we are constantly circling back through SCEM to make sure these fundamental requirements are being met.


This week in this Part 2 of our decision making process, I will do my best to summarize the more specific criteria we use to ultimately make our final decisions upon.  I will cover this as a series of the following questions that we ask and answer to our satisfaction at least, as we evaluate each bit of kit and then use these to make our call.

  • What problem is this item attempting to solve?
  • Is the problem/item a want or a need?  
  • Consequences of adding this item?  Domino effect?
  • Does it pass the Goldilocks test? 
  • New vs Tried & True?

What problem is this item attempting to solve?

Might sound like a silly question at first but it is surprising how often answering this question provides the most help in in our evaluation of a design decision or of a given piece of equipment.  Let me use our decision of what battery type to use for our House Battery Bank to illustrate but one example of how valuable this question was. 

To put this question into context, keep in mind that Möbius is a completely Battery Based Boat, meaning that ALL of our onboard electrical power comes from our House Battery Bank and therefore this is one of THE most critical systems on the boat and one that in some cases our lives can depend upon.  For an XPM or any true eXpedition boat that is going to be able to carry us safely and comfortably to locations across the full spectrum of eXtremes of climate and remoteness, we need to be as self sufficient as possible and so our onboard electrical power rates right up there alongside diesel fuel and fresh (potable) water as a critical requirement.  An XPM type boat is designed to spend the majority of its time at anchor or at sea, in our case often for months at a time, so in all our design and equipment decisions, we assume that we will have no shore based resources such as shore power, stores, shipping, airports, etc.. 

XPM Electrical System w 4 Batt BanksFinally, for a bit more context, let me add that we have also chosen to not have an independent generator onboard so ALL of our four voltages, 12 & 24 Volt DC and 120 & 230 Volt AC, come from our House Battery Bank.  Most of the time we keep our batteries charged via our 4.48kW array of 14 320W Solar Panels and when underway we have 12-14kW available from the two eXtremely robust 250A @ 28V Electrodyne alternators which Mr. Gee keeps spinning.
One of the very first decisions we needed to make to chose our batteries was what type or chemistry of batteries would be the Goldilocks just right, just for us House Batteries?  I’m not going to go over this in any detail here but these are the five battery types we had to chose from:

  • FLA;  Flooded Lead Acid
  • AGM:  Absorbed Glass Matt
  • GEL: 
  • Carbon Foam
  • Lithium

Many of you and others we talked to, thought for sure that the choice was obvious; go with Lithium and we did consider them, and all the other types, very thoroughly.  But it was that question of “What problem is this trying to solve” that made it clear that Lithium was not the best choice for us and that’s the story I’d like to elaborate on here a bit.

Victron Gel-OPzV-1000ah-batteriesOur battery decision making started at the very beginning of our design process, around 2016, and in some ways we designed and built the boat around the House Batteries. For the first few years, we thought we would go with GEL based OPzV batteries such as this one.

These OPxV type batteries are eXtremely robust and often referred to as “traction batteries” as they are used in things like all electric forklifts in warehouses so they had good cycle life and good resistance to sulfation and other features that wold make them a good choice for Möbius.

During this time we were reading more and more about Lithium batteries and we were seeing more and more people who were choosing to go with them so we also spent a good bit of time researching the various types and makes of Lithium, primarily LiFePO4 or Lithium Iron.  This relatively new type of battery was said to have a lot of amazing features with the top ones being longer lasting (more cycle life), ability to accept much higher charging rates thus take less time to charge, but perhaps the biggest feature was their much higher energy density.  This means that you get much more usable Watts from the same amount of space and weight compared to what you would get from other battery types.  Said another way, you could get the same amount of energy out of a much smaller size and lighter battery bank.

As the months and years went by, these claims were validated more and more and we saw the steady increase of Lithium Iron being the batteries of choice for more and more boats so it seemed like the choice was clear right?  However when we applied our criteria and use case and asked the “What problem is Lithium trying to solve?” question, we realized that we didn’t have the same “problems” as most of these other boats such as size and weight of our House Batteries. 

My earlier comment that we had designed the boat around our House Battery Bank is not that far off as we had designed the hull to take maximum advantage of the characteristics of our original consideration of OPzV batteries which were very large and very heavy.  Each OPzV 2/4V cell measured 215mm/8.5” Wide x 277mm/10.9” Deep x 855mm/33.6” High and weighed 110kg/242lbs each, and we needed 24 of these! 
FireFly House battery bankAs we often do, we turned this “bug” into a feature and built four large battery compartments into the framing of the bottom of the hull such that each compartment straddled the 25mm thick x 350mm high keel bar running down the centerline of the hull.  By positioning these battery compartments on the very bottom and center of the hull, we effectively turned the lead in our batteries into a proxy for some of the lead ballast we needed.  This is a photo from last year of one of our four battery compartments.

The point here if you are following along with me is that for the use case and design of an XPM, the “problem” that Lithium batteries would solve with their high energy density for a given weight and size just wasn’t a problem we had; we had the room and we wanted the weight.  So the search for our Goldilocks batteries continued.


FireFly L15  4V-battery photoFor awhile we continued to think that OPzV Gel batteries were the best fit for us, however, just as we had been following the developments of Lithium batteries we had also been tracking the growing use of Carbon Foam type batteries from FireFly.
They ticked all the boxes on our list of criteria, most notably these were proving to be eXtremely robust and several attempts by test labs trying to purposely destroy these batteries failed and they proved to be almost indestructible which is a huge factor for us and our use case.
FireFly House battery bank with DC control panelThese Carbon Foam batteries are also able to work and charge in much lower temperatures such as those we expect to have when we are in polar regions of the world and they are one of the only battery types that don’t suffer from sulfation. and are happy, even recommended, to stay at Partial State of Charge for long periods of time which would normally be the death of most other batteries.


Near the end I found real world installations of these batteries, some of which had been in place for more than ten years and so just before placing this large order of batterie we changed and ordered 24 of these 4V  L15+ size Micro Carbon Foam batteries which now make up our 43.2kW House Bank (1800Ah @ 24V) made by FireFly and they have been working flawlessly for the past six months.

Let me be clear that I am NOT saying that Lithium batteries are not a great choice for many boats, nor am I saying that Carbon Foam batteries are “the best”, I am just hoping to explain how and why we made our decision to go with Carbon Foam and why they are the Goldilocks just right, just for us choice.  All thanks in part to the question we regularly ask near the beginning of our decision making process; What problem is this trying to solve?

Is the problem/item a want or a need?  

We often put each item we are trying to decide on into either the Need to Have or Wish/Want to Have category.  Pretty self explanatory I think, Need to Have are items that we feel are mandatory must haves in order for us to feel confident in going to sea and living full time aboard Möbius.  Examples for us include things like;

  • our high output watermaker,
  • Furuno Radar and other navigation equipment,
  • eXtremely high amounts of acoustic & audio insulation,
  • comfortable Helm Chairs,
  • that little FLIR One thermal camera I used to find the overheated wiring a few weeks ago,
  • great HVAC systems
  • Global communication capability (right now via our Iridium GO)
  • and items like this.

The Want/Wish to Have category can be subdivided into groups such as;

  • buy as soon as the budget allows
  • later when it is ready for real world use (ours)
  • nice to have, perhaps a gift to ourselves or each other

Current examples on our Wish/Want list includes things like:

  • second Furuno Radar with NXT technology,
  • forward facing sonar when it is has been in more mainstream use and is robust enough for our use case
  • active stabilization, most likely Magnus Effect type
  • kite sail with autopilot to add to our propulsion and reduce fuel usage
  • Portland Pudgy, Christine’s long time wish for a small, light sailing dingy
  • affordable high speed internet such as that being promised by 5G and satellite based systems being developed.

We also have a third category worth mentioning which is the Don’t Want Onboard category which is sometimes the best choice.  Items on this list would include things like;

  • anything that requires propane (too much of a pain to fill around the world)
  • anything that requires gasoline (too short a shelf life these days)
  • Generator
  • Guns/weapons

Consequences of adding this item? 

As a good friend and fellow world sailor likes to say “Everything needs” and so we spend time trying to imagine what the needs and other consequences will be if we add this bit of kit to Möbius.  Our primary prioritization of Maintenance, lack thereof, would factor into this for example and hence decisions such as;

  • no paint/wood/SS on the exterior,
  • being single fuel boat with no propane or gasoline,
  • no generator

but it could also be other consequences of adding this item to our boat.  An XPM is complex by virtue of needing to be so self contained and as we often say Möbius is like a floating village in that we have to look after making all our own water, all our own energy, dealing with all our own waste and so on, but we do strive to apply the KISS or Keep It Simple & Safe philosophy to all our decisions by finding the simplest solution possible.  Examples of this would include:

  • manual roll attenuation with our fully mechanical/manual Paravane A-Frames
  • manual Tender Davit system vs hydraulic
  • Gardner engine (no turbo, no electrics, low revs, etc.)

Domino Effect?

The Domino Effect is perhaps a branch of the consideration of the Consequences of any decision as I just outlined above and is when the result of a decision has follow on effects to other systems on that boat.  This can work both ways; sometimes these dominos are positive ones and in other cases they are negative or undesirable consequences.  For example, installing the eXtreme amount of EPDM and acoustic insulation throughout the boat has a domino effect;

  • stabilizes the interior temperatures and makes them more temperate in both very hot and very cold climates
  • this reduces the energy required to cool/heat the boat
  • this allows us to install smaller capacity and less expensive HVAC systems such as Air Conditioning and heating
  • this lowers the demand on our House Batteries and HVAC systems so they run with less loads and last longer

An example of when the Domino Effect can work the opposite direction might be the option we considered of installing fin type active stabilizers.  These work extremely well to reduce the roll in many conditions when on passages but they would also introduce a Domino Effect of consequences that took them out of the running for us, such as;

  • their protrusion from the side of the hull reduces the safety factor when in areas with uncharted rocks, coral heads and the inevitable groundings on these.
  • not suitable when ice is present in polar waters
  • unlikely but possible if a fin is hit hard enough to create an underwater breach of the hull
  • are extremely complex and often top the lists of most maintenance problems we read from other global passage makers.
  • most require a significant hydraulic system to operate which adds yet another whole system onboard to maintain and repair.

Magnus Effect illustrationI might add that having gone through this Domino Effect as we considered active fin stabilization, it also helped us see that we could find a different type of active stabilization if we should ever want that, and one that eliminates most of the dominos I listed above.  This would be stabilizers that use the Magnus Effect which is offered by several different manufacturers now.

Does it pass the Goldilocks test? 

We essentially answer this question by virtue of having gone through all the questions and priorities I’ve already listed.  Because we have highly personalized our overarching principles of SCEM and articulated much more detailed specifics of our use case, our decision making helps us ensure that we are making choices and decisions that are by definition, Goldilocks, just right, just for us.

However, this is such an important factor for us that we do keep coming back to to this “Goldilocks Test” to make sure we are avoiding the tendency to “go with the flow” of following what others are doing or “the way its always been done” and are staying true to ourselves and our preferences.  I will site a more “meta” example here which is our decision in the design phase to “upsize” the length of the boat from the 18-20m / 60-65 ft that we initially imagined and then at the same time “downsize” the interior to have just 2 cabins and 2 heads.

Our decision to extend the length to 24m/78ft was driven two factors; simple physics that hull speed is a factor of Length on the Waterline and our discovery that contrary to popular opinion there is not very many restrictions on boats that are over 20 meters whereas there are some very significant changes to the rules governing ships that are over 24 meters.  With our prioritization of efficiency, we pushed the length to just under 24 meters.  With our infrequent use of marinas the increased docking fees do not affect us very much.  Furthermore, with more and more catamarans being purchased, many marinas are changing their dock rates to be calculated based on overall area of each boat, LOA x Beam and so our slender 5m Beam reduces our overall area and we are often cheaper or about the same as much shorter but wider boats.

Our decisions to “downsize” the interior and thus reduce maintenance and costs was based on the fact that 99% of the time Christine and I are the only two people living onboard so we wanted to make the interior fit us and our needs.  Our Master Cabin is very spacious and luxurious for us.  Our Guest Cabin works very well when we do have guests onboard but most of the time it is a very purposefully designed Office for Christine Kling, the Captain’s nom de plume when she is working on her next book and running her growing book business.  Our SuperSalon is indeed living up to that name the more we live in it.  And my very full size Workshop and Engine Room is that of my dreams. 

There are many other examples of how the Goldilocks Test has driven our decisions such as;

  • Manual Paravane system and Tender Davit that is KISS and as former sailors handling lines, winches and clutches is second hand.
  • Though we designed and built the cabinets, electrical and plumbing for them, we chose not to install either a Dryer or a Dishwasher as we are just not fans of either one and prefer washing and drying by hand.

I could give countless more examples of how we have applied the Goldilocks Test to almost every decision we have made during the design and the building process but I think you get the idea.  We have now been living aboard Möbius since she first launched in February and we are finding that our continuous use of this Goldilocks Test has worked eXtremely well for us in designing and building Möbius and we can and do recommend it highly for almost all decisions and choices you make.

New vs Tried & True?

Christine and I are self described nerds and geeks so we have a great fondness for technology that is on that well named “bleeding edge” and we have a full compliment of devices to show for it.  However, when it comes to equipment for Möbius, and especially all of it that is on that Must Have list, it must be remembered all those decisions must be made within the context that Möbius is an XPM type boat that is designed and built to live up to that acronym for eXtreme eXploration Passage Maker.  So when it comes to deciding on equipment, materials, construction and design of these items, they must, all be Tried & True.  To us this means equipment that has been in regular use on boats, ideally with similar use cases as ours, for several years and has stood that test of time.

Some examples of this for us include:

  • we delayed our decision to go with FireFly Carbon Foam batteries until after we had been able to find enough examples of these batteries being installed in other people’s boats in large numbers for many years.
  • We chose to go with all Furuno for navigation because it is so widely used by commercial boats in fishing fleets, government agencies and the like and hence this equipment is designed and built for continuous 24/7 use in some eXtremely harsh conditions.  They also have an excellent reputation for their continued support of even their oldest equipment.
  • Our decision to go with a Gardner 6LXB engine that is still one of the most efficient diesel engines ever produced and is still in use in thousands of commercial boats worldwide.  It is also perhaps one of the best examples of the KISS approach to design and engineering which adds to how well it passes the Tried & True test.
  • individual MPPT controllers for each of our 14 solar panels as this has been well proven to be the most efficient combination for both overall efficiency, least affected by shading and highest redundancy.

Let me end with a final example of the value of taking this Tried & True test for mission critical ships and equipment from no less than the US Navy!
US Navy Gerald Ford aircraft carrierA recent article caught my eye a few weeks ago where even the us Navy has learned the folly of installing untested equipment on their ships.  This link to the article  USS Gerald R. Ford Problems: The Navy Admits Its Big Mistake (popularmechanics.com) provides a brief but telling story.
US Navy Gerald Ford aircraft carrier side viewas outlined in that article the Chief of Naval Operations, Mike Gilday, says the U.S. Navy built the aircraft carrier USS Ford with too many new technologies. such that now, the Ford is several years behind in its life cycle because of problems with many of those new technologies.

  • The last of the Ford’s four advanced weapon elevators, the most glaring example of the ship’s tech gone wrong, should enter service later this year.
  • When the Navy first built the Ford, it incorporated nearly two dozen new technologies, some of which are still giving the service headaches 4 years after the ship entered the fleet.  Those delays meant the Navy only commissioned the Ford in 2017, despite laying it down in 2009. Even then, problems lingered, especially with the electromagnetic aircraft launch system (EMALS) and the advanced weapon elevators (AWEs).
  • The ship’s first full deployment, originally scheduled for 2018, is now set for 2022.

I think this unfortunate real world example does help to make the point that for XPM types of boats with use cases to match, all the “mission critical” equipment onboard MUST have passed the Tried & True test.

Bubble Bubble, Toil & Trouble!

PXL_20210811_143412922.MPLeaving you with the latest bit of kit that Captain Christine just approved and installed onboard, a fully manual sparkling water maker!  Especially in these hot summer months, Christine particularly enjoys her cold sparkling water and I do too but we don’t like having to buy it in cases of plastic bottles.  We have our watermaker for similar reasons for our regular drinking water.  Initial tests have elicited the same smile you see here so this item has now passed the all important Captain’s Test and has been welcomed aboard.
Thanks so much for making it this far if you have and I do hope that this slightly different format and content is of interest and value to most of you.  Let me know either way with your comments in the “Join the Discussion” box below and I’ll be back with more for you same time next week.

-Wayne