I am VERY pleased to be able to report that everyone on Team Möbius including Christine and myself are all doing well and managing to stay safe, fit and healthy. As per the title the only thing we are “infected” with is enthusiasm and progress. We certainly hope this will continue although the numbers of cases and deaths in Turkey while still relatively low compared to most other countries, have continued to climb. There is a general “stay home, stay healthy” recommendation for all and requirement for some, face masks are now required in grocery stores and the like and more and more cities, including Antalya where we are, have been closed for travel in or out. Hopefully the escalation of these defensive restrictions and regulations which will outpace the virus and be effective in flattening the curves.
On the good news front, I was delighted to end my two weeks of self isolation after our trip to London last month and rejoin the rest of Team Möbius back at Naval Yachts on Monday. I have made several changes though such as moving my office into my Workshop so that I can now spend 98% of my time still quite isolated and well distanced and I now only go aboard Möbius when everyone else is off the boat on their tea, coffee and lunch breaks. This has been working well and I have been able to get back to photographing all the progress so let’s jump right in and show you what’s been happening this past week.
I think I will organise this weekly update by starting at the front of the boat and working my way aft so let’s go up to the Bow.
FOREDECK ANCHOR GEAR
If you read last week’s Update you recall seeing that Uğur and Nihat were getting ready to mount the Maxwell VWC 4000 windlass and this is the final location they have marked out. The long line is the centerline of the anchor chain as it comes back off the shank of the 115 kg/242 lb Rocna anchor though that side mounted bow roller chute. The circle is the main body of the windlass gypsy and capstan and the small holes are where the studs from the Windlass body go down through the 15mm/ 5/8” AL deck plate and are secured from below to the 24V motor and gear assembly. Down inside the Forepeak looking up at the spot where the Windlass will mount you can see the extensive 10mm / 3/8” stringers underneath that 15mm deck plate. Some of you were asking about our Chain Bin so here is a better shot of that. Having a relatively small and round area for the chain to pile up in helps keep the chain from “castling” very much and falling over on top of itself which prevents the chain from becoming tangled and difficult to put out.
The Chain Bin itself is about 70cm / 28” in diameter and about 1.5m / 60” tall with a drain in the bottom which exits out through the side of the hull just above the waterline. I had put in a similar drain in the chain locker of our previous boat and it worked extremely well to automatically drain any water and muck right back out and a good rinse from the washdown hose every once in awhile kept it clean and pretty much odorless.
There will also be a clear plastic “gaiter” fastened around the top of the Chain Bin and the bottom of the deck to contain any water and muck that might want to fly off the chain and mess up the Forepeak.
Just aft of the Chain Bin I can show you this detail of these two built in SS Quick Connect fittings on the aft end of the Anchor Deck. One connects to the Fresh Water wash down pump and the other to its Salt Water sister which makes cleaning up the chain as it comes aboard very easy as well as keeping the whole Foredeck nice and clean.
The White PVC pipe is the Compressed Air line that runs the entire length of the boat for pneumatic tools, blowing things up and cleaning. The larger clear hose is one of the vent lines for the large water tanks below the Master Cabin sole.
Uğur and Nihat were also able to finish up one of the two Fresh Air manifolds that go up in the ceiling of the SuperSalon. This is the forwardmost one that sits overtop of the Main Helm and then a second one is about 2 meters aft of that in the center of the SuperSalon. Looking on the other side these 5 vent tubes set well above the bottom of this air plenum or manifold and have manually activated vent lids which can be pulled down tight to seal off each vent entirely if things get really rough and we want to shut off the air flow entirely and keep any errant water out. Looking up inside one of the vents you can see the simple cross knob that you can easily turn by hand to move the lid with its rubber seal up/down as needed. Keep it Safe and Simple or KISS it right?
Moving Aft into the Master Cabin, Selim and Şevki have been continuing installing the ceiling grid and snap in panels. This is standing beside the Shower on the Right looking towards the Aft Port/Left corner of the Master Cabin.
Bed on the far Left with all its drawers underneath and the dropped ceiling above. Some of the leather covered snap in wall panels on the Right have been remove while Cihan is putting in the black ducting behind the wall grid for the AirCon/Hot Air to flow from the Air Handler underneath inside the narrow floor you can see in the photo above up to ………………….. …….. this beautiful Rosewood vented air box up on the ceiling. Turning a bit to Starboard you can see the stairs leading up to the SuperSalon are ready for their treads to go in and Christine’s Bosch Washing machine, with WiFi no less, is setting atop the bed frame ready to be installed in its forward cabinet soon.
For those wondering, they have painted the ceiling grid Black to create a nice contrast to the narrow space between each of the White leather covered ceiling panels when they are snapped into their FastMount fittings in each of those small holes. Spinning around 180 to look forward you can see they have done the same to the rest of the ceiling grid up front.
Master Shower in the Left foreground with its adjoining Head/Bathroom behind. The rough ceiling panels have now been fitted and snapped into place in that forwardmost area with the Bathroom/Head on the Left, Vanity sink area in the center and the Wardrobe cabinetry along the wall on the Right. The washing machine will be installed in one of these upper cabinets. Zooming in on this nice bit of detail where three of the ceiling panels meet up on the small corner around the Bureau of Drawers that is on the far Right.
MASTER SHOWER & HEAD/BATHROOM
The Master Shower/Bathroom continues to get fully glassed in.Shower is in the Left foreground and the corner walls here will be etched glass. Shower seat on the bottom Left with the Bathroom countertop extending all the way to the far wall with the toilet mounted on the raised floor platform to the Right.
There will be a clear glass half wall inserted in that slot between the Shower seat and the Sink cabinet on the Right which will separate these two compartments and keep the Bathroom dry. The two upper “Medicine cabinets” as I grew up calling them have been clamped in place ready to be glassed in.
There are removable backs inside these cabinets to provide easy access to the plumbing behind the wall.
The hole in the ceiling is where fresh air flows in from the Dorade Vent above and you can just see the corner of the large hatch above the Shower and part of the Bathroom to bring in more fresh air and LOTS of natural light.
VacuFlush toilet mounts to this black flange on this raised platform and the rectangle in front is to provide access to the water tank access port underneath.
The Shower and Head will each have lift out Teak covered floor plates so all the water drains off their edges into the seamless floor pans below and out the drains into the Gray Water pumps. Just outside the Head/Bathroom door frame on the Left is the Vanity Sink with its own upper cabinet on the wall and another big hatch above.
SUPERSALON & MAIN HELM AREA
Omur and Selim made lots of progress in the SuperSalon and Main Helm areas this past week. Looking towards the Bow and down the spiraled stairs you can see all the drawers on the side of the Bed in the Master Cabin below.
Arm of the Settee in the bottom of this photo and Main Helm above. Standing in the opposite corner at the bottom of the other stairs coming down from the Aft Deck gives a better sense of the overall layout of the Galley on the Right, Helm up front and double Fridges cabinet on the Left.
Hatch into the Basement in the center. A good glimpse at some of the craftsmanship details of this Port/Left corner of the Helm area. Our ubiquitous BHL Blue Horizon Line continues winding its way through the boat. Peering down inside this triangular cupboard gives you an idea of just how cavernous and deep this space is thanks to the dropped ceiling overtop the head of the Master Bed below. There will be a Black leather covered lift up triangular door on top here to reduce any glare in the negatively raked window glass at night. This center area of the Helm will have a sloped dashboard panel with two 19” touchscreen daylight readable monitors set in behind it just in front of this center window. On the Right side of the center Helm Chair this sloped wall provides more area for Helm controls and switches.
Forward electrical panel inside this area and Hilmi has started to fasten in some of the many cables coming up from the Basement. Most of our 24V circuit breakers and some electric system monitoring gauges will be inside. The far Starboard/Right side of the Helm has a matching triangular storage area. This one isn’t quite as deep to provide plenty of headroom through the doorway below. Can you guess what Omur and Selim are making up here?
Hint; they also go into the SuperSalon area hence my including them here. Full marks if you were able to guess that these are the corner brackets to make the transition between the top of the window frames to the ceiling. These will go all the way around the whole perimeter of the SuperSalon windows. One detail some of you fellow DIY and Makers might appreciate is this thin phenolic based layer they laminate to the marine plywood surfaces to provide a perfectly smooth surface for paint and leather to be applied. Quick and easy to laminate onto the plywood surfaces and then trim the edges flush with a router bit. Glue and paint stick tenaciously to this material without any raising of the grain of the plywood or need for multiple coats to fill the porous wood below. Another detail I received several questions about is this thin acrylic sheet I have in my dirty little fingers here. It starts out as a sheet of thin 2-3mm clear acrylic which we then had our aquamarine swirl photo printed onto the underside surface. Once back from the printer these are easily sawn into strips for the Blue Horizon Line which you can see stacked up in the background.
A heat gun softens the strips where they need to wrap around radiused corners and are easily glued into the recesses behind the Rosewood hand holds and other edges such as these winding around the Settee bottoms.
More of our 360 degrees of BHL snaking its way around the Galley cabinets just under what will soon be the aquamarine granite countertops. Galley Garages are back from the Finishing Shop and being fit in place. Foundation framing being completed so that the rigid foam floors can be put in place and the grooves for the In-Floor heating PEX tubing can be cut. Once he had all the last of the floor frames adhered to the AL plates Selim got to work cutting and fitting all the rigid foam insulation. He then cuts and fits the 10mm / 3/8” marine plywood flooring. These are just dry fit for now as they need to come up for the installation of the In-Floor heating PEX tubing before they are finally glued and screwed to the frames. The finish floor will be strips of some new “click locked” vinyl flooring that is now used in airports, shopping malls and other high traffic applications.
Down below in the Guest Cabin, Omer and Muhammed have been hard at work putting in the removable ceiling panels. Same system as we saw earlier in the Master Cabin with the Black ceiling grid to provide some depth and contrast in the space between the White leather covered ceiling panels when they are snapped into place like these three overtop the bookshelves hiding behind their protective cardboard coverings. And these ones overtop the Pullman Berth and …. …… Christine’s Office Desk with its own Bookshelves above.
Rosewood box on the Left of her desk provides some of the support for the Pullman when it is pulled down as well as being ……………… ……………………… a removable cover giving access to the Air Handler inside that corner cupboard. They have also been busy installing the sink cabinet and surround in the Guest Head with more of the BHL of course! Ro$ewood countertop being attached. Sink will be atop the counter on the far Right with storage cupboard below. On the other side of the Bathroom wall Omer and Muhammed have been started work on the BHL and handrail leading up the stairs.
Boat Office (aka mine!) on the Left. Carefully fitting and gluing the BHL strips into place.
On the opposite side of the photo above, behind Omer’s back we see some of Hilmi’s handiwork putting in the nautical miles of cables and wires.
This is the Aft Electrical Panel which will be home to most of our AC DIN rail circuit breakers as well as some more 12 and 24V equipment. This is the Forward Electrical Panel we say earlier on the Right side of the Main Helm which holds most of our 24V circuit breakers, switches and gauges. As you can see Hilmi has most of these cables coming up from the Basement, zip tied to the bottom for strain relief and ready for connecting all these wires to their respective circuit breakers, switches, controllers and gauges. Down in the Basement he has also been hard a work putting in more of the N2K network and Maretron monitoring system. Another AL panel in the diagonally opposite corner of the Basement with more Maretron black boxes and one of the blue multi-port boxes on the N2K Backbone. Looking up, we can see that the wire trays are starting to fill up with all the different cables and wires going in and out of the Basement which is purpose built to be Grand Central Station for all these systems.
Back in the Workshop, Cihan’s plumbing handiwork is evident with examples such as this set of ball valves for the sea water going in/out of the Sea Chests in the Engine Room. These four are the sea water supply and return lines for the Delfin Watermaker’s low pressure Feed Pump and the Webasto Chiller’s circulation pump. Above these ball valves are more lines for Domestic Hot & Cold Water, Chiller water and bilge pumps. Looking forward alongside the Engine Room walls on the Left and the Day Tank in the upper Left corner you can start to see just how much work Cihan has been doing putting in all these hoses and ball valve manifolds for everything from fresh and salt water, Bilge and Gray water lines, fuel lines and compressed air. Here for example are some of the many hoses going in/out of the Engine Room on the Left with the deep sump of the Day Tank above with its blue handled ball valve for easily draining off any water and dirt that collect there. Up on top of the Day Tank Cihan is starting to plumb in the fuel lines to their respective ball valves across the top.
One of the more exciting new developments this past week was Uğur and Nihat’s work putting in the framework for this very cool composite grid that Yigit found for us. This is normally used for walkways in high traffic industrial settings and marinas for example. It is about 35mm / 1.4” thick and comes in sheets about 1m x 4m long. Easily cut with a circular saw or hand tools and impervious to everything from fuel to acid so should work really well for flooring in the Workshop, Engine Room and Forepeak. So Uğur and Nihat got busy putting in a whole framework of L-bar for this flooring grid to attach to. This is the floor alongside the Port/Left side of the Workshop/Engine Room with the WT door into the Guest Cabin/Office area at the far end. On the Stbd/Right side Uğur tacks in the L-bar frames around those Sea Water ball valves we saw earlier. Doesn’t take him long to get this all tacked up and all leveled as it extends all the way forward to under the Day Tank. Using this system we are able to keep the Workshop floor all on the same level by framing around the Prop Tunnel as you can see here. There is a center workbench directly overtop the bulge of the Prop Tunnel with storage below so the large thick arched frame member does not impede walking around the aft end of the Workshop.
Nihat and Uğur were in top form this past week as they also put in this very special milestone; the installation of the Aft window frames and …… ……. Aft Entrance door from the Aft Deck into the SuperSalon.
These have been purposefully left out up to now to make it easier to bring all the cabinetry and large equipment in/out of the interior but with all that now done these last bits of the aluminium framing can go in.
If you look closely at the top of both vertical door frames above you can see these oval cut outs which enable us to use them as well protected chases for wires and cables running from up in the SkyBridge and down into the SuperSalon and Basement. On the outside on the Aft Deck you can see how the window frames provide the same recesses for the 28mm / 1.1” tempered glass windows. Once the welding was done and cool, Nihat started putting in the EPDM insulation on these new AL surfaces. They were also able to cut these large holes in the Upper Aft corners of the SuperSalon which connect into the Upper Wing Vent Boxes that extend aft on both side of the Pilot House. There will be a large axial extraction fan inside each of these Vent boxes to pull air out of the Galley (shown here) and SuperSalon areas and keep a good flow of fresh air throughout this large living space.
AFT DECK VENT BOXES & OUTSIDE GALLEY
But Wait! There’s still more from the Dynamic Duo of Uğur and Nihat
Clearly “infected” with enthusiasm Nihat and Uğur also worked on lots of details on the two large Vent Boxes you’ve been seeing take place over the past month.
This is one of the Extraction Fan boxes which Yigit cleverly designed. A large axial fan will be mounted inside this box pushing air out the top 5 slots and the bottom is sloped so that any water that gets in here can quickly drain out those bottom slots. Here is another extraction fan boxes of Yiğit’s same design and this one mounts on the Lower Wing Vent Box just outside the Aft Entrance Door. Inside, you can see 2 of the round air ducts coming up out of the Corridor and Guest head below with the same shut off lids we saw at the beginning of this post so that these vents can be completely closed and WT if things get really nasty outside. Also in the Vent Boxes and something I received several questions about was these Mist Eliminators so I wanted to provide some more examples and explanation. These flush mount on the inboard sides of the Vent Boxes and their specially designed set of fins inside cause the incoming salty air to give up most of its moisture and also break up any full hits of water that might splash up this high. If you look closely inside (click to enlarge any photo) you can see the fin shapes and also the drain in the bottom that will have a drain hose attached to take the water back out to the deck. Looking down deeper into the Port supply air Vent Box you can see the entryway duct heading down ….. ………….. into the Engine Room through this long AL duct which brings the cool dry outside air down to the floor of the ER to help maximize the natural flow of air as it warms and rises up to exit out the extraction vent up on the ceiling of the opposite side of the ER.
PROP SHAFT in the RUDDER
Finishing the tour at the very Aft end of the boat to show you this last bit of aluminium work Uğur and Nihat completed this week with the final welding of the prop shaft removal tunnel in the rudder. A small but highly valued feature that makes it possible to remove the Prop Shaft without having to also remove the Rudder which is not a quick or easy thing to do. Nice work boys!
Spending almost all my self imposed “shelter in place” time at the shipyard in my reorganised Workshop, one advantage is that I am now able to devote more time to Mr. Gee as we affectionately call our Gardner 6LXB main engine.
In previous weeks I had sandblasted, scrubbed, pressure washed and primed all the main aluminium castings and this week I was able to apply the top coats.
He has cleaned up very nicely for a 50 year old guy don’t you think?
Brief Tech Talk:
For those interested, I’m using a special high temp silicone based paint and the primer is rated for up to 600C/1112F and the top coat here is rated at 300C/572F which is way beyond any temps Mr. Gee should experience. The topcoat you see going on here, is basically aluminium dust mixed into clear silicone. Works great and looks like brand new aluminium which was my goal. I was originally going to leave all these castings in their natural “raw” sandblasted aluminium state but the nature of cast aluminium is that it is quite rough and porous which tends to retain oil and dirt. So I decided to paint all these surfaces not only because I wanted Mr. Gee to look good, I also like to have light coloured and very smooth surfaces on my engines so that they are easy to keep clean and more importantly easy to spot any leaks right away.
I found that even when the aluminium top coats were fully cured, when you rubbed these surfaces with your fingers or a clean cloth, some of the aluminium dust particles suspended in the silicone would come rub off, so I put on two coats of clear to create a smooth and impervious final finish.
LOTS of work as you might imagine, but well worth it and I am eXtremely happy with the end result both now and over the next few decades of Mr. Gee’s next life.
Various cast AL covers which bolt to the Crankcase also received their fresh new aluminium and clear coats. This first half of the flywheel housing will soon be bolted to the end of the crankcase above and then …… ……. has its other half here bolted on to complete the housing with the monstrous flywheel fully enclosed inside.
The SAE1 bolt pattern on this housing mates with the SAE1 pattern on the Nogva CPP Servo Gearbox to create a single solid propulsion unit that drives the 65mm/2.6” diameter Nogva prop shaft. This is the “tiny” little cast aluminium oil sump/pan which I’d estimate weighs over 22kg / 50lbs by itself. Ask me how I know! It holds 27 Litres of oil.
All surfaces are fully finned to increase the cooling of the engine oil and then there is an additional dedicated engine oil heat exchanger that was the next focus of my attention this week. This is the solid bronze engine oil cooler which runs along the side of the crankcase.. It is a heat exchanger style cooler with sea water pumped into it through the bronze 90 degree elbow in the Right foreground and out the arched pipe you can see on the far end and in the photo below.
Engine oil is pumped into the flanged fitting in the Left foreground ……… ………. which then exits out a similar fitting on the far end which has an external copper pipe that carries the cooled oil back into the oil sump.
There is a dedicated gear driven oil pump to move the oil through this cooler.
Keeping the engine oil at a consistent temperature is one of the keys to the eXtremely high efficiency these Gardner engines have, hence this dedicated oil cooler. Didn’t take me too long to disassemble the oil cooler and you can now see how it works. The hot engine oil flows through that cool looking crimped bronze tube in the middle here and the cool sea water is pumped through the two part square cast bronze tubes on either side. Classic Gardner over engineering that I never get over.
Not seen here, but there is a replaceable long thin strip of zinc anode that runs inside the full length of the cooler so that it rather erodes rather than the brass or bronze parts due to the natural galvanic corrosion that is a function of dissimilar metals immersed in electrolytic sea water.
One of Christine’s many birthday presents! This close up of one end lets you see how the sea water flows through the outer square area surrounding the round crimped brass tube in the middle which has the hot oil flowing through it.
Last but definately not least for this past week was this newest arrival.
Can you guess what’s inside? While you ponder that, I want to be sure to give an eXtremely big XPM Möbius shoutout to the people who were so great to work with to make this happen:
Thanks to Rob Westermann who runs Artnautica EU over in Hindeloopen Netherlands along with with our XPM designer Dennis Harjamaa at Artnautica HQ over in Auckland New Zealand. Rob has become a good friend of Christine and mine as well as Naval Yachts and it was only thanks to his extensive network within the marine industry and especially in the Netherlands that we were able to work out this Goldilocks water heating system with Kabola. I’ve been a big Kabola fan since first encountering their super efficient diesel water heaters or boilers more than ten years ago so it brings me great joy to finally have this aboard our new home Möbius.
I also want to thank Othni and Roelof at TCN Techno Center Noord the Kabola distributor in Sneek NL who worked with me through all the technical detailing and engineering of our diesel fired hot water system.
And most recently, kudos to Hugo at Clion-Marine Eberca B.V. who was an ace at getting this shipment through to us in these challenging Corona virus times. Fortunately air freight flights and the global supply chain still seem to be up and running in most parts of the world and I’m hopeful this will continue. Fortunately we now have pretty much all the equipment we need for the build so shouldn’t need too much more but with boats there is ALWAYS something more you need it seems.
Thanks to all of you!
So as you might have guessed by now, this week’s New Arrival was our Kabola KB45 EcoLine Combi diesel fired water heater fresh off the plane at Antalya airport from where they are made in the Netherlands!
These newer Kabola EcoLine models now have all digital controls and thermostat by Siemens and they average about 94% efficiency. You can hold a white rag over the exhaust outlet and not catch a trace of soot and I’ve seen some of these being opened up for maintenance after 2+ years of steady operation with almost no soot in the burner itself at all. We ordered the full Kabola exhaust system which helps to keep the exhaust almost silent when it exits out the hull and very low heat escapes through the double walled heat exchanging exit pipe.
The “Combi” version of these Kabola EcoLine boilers has two independent water circuits; one to help heat the Domestic Hot Water in the central Calorifier aka Hot Water Tank, and the second circuit to heat the interior air in the boat via the Webasto A-Series Air Handlers in each room. Here is how that all works:
1. One of the circuits in the Kabola boiler heats fluid circulating through one of the two heat exchanger coils inside the IsoTemp Calorifier (Hot Water tank) which is the source of all the DHW Domestic Hot Water that circulates throughout the boat to supply each sink and shower.
This cutaway model at the Dusseldorf boat show lets you see inside a single heat exchanger coil model.
Our model of these Webasto Indel IsoTemp Calorifiers has a second heat exchanger coil inside that circulates some of the hot fresh water/antifreeze coolant from the Gardner engine so we get “free hot water” whenever Mr. Gee is running.
And if you look closely in the cutaway model above, you can see that there is a third heating source in the center which is a traditional 230V electric coil. Not being connected to shore power we would rarely use this but could prove useful sometimes.
2. The second circuit being heated by the Kabola KB45 boiler heats fluid going to any of the four fluid to air heat exchangers inside each of the Webasto Air Handlers or “Fan Coils”; one in each Cabin and one on each side of the SuperSalon. When supplied with hot water these heat exchangers or Air Handlers, transfer the heat from the fluid to the air blowing through them and warm up the space this way.
These are the same Air Handlers double as our Air Conditioners in hot climates simply by having the Chiller feed them chilled water instead of hot. Single units, dual purposes, which we try to do with as many of our systems as possible.
Of course whenever we are in colder or Polar climates we will most often use our In-Floor heating system which runs through three independent zones; Master Cabin, Guest Cabin and SuperSalon. The In-Floor heat also comes from the Domestic Hot Water circuit coming out of the Calorifier so we get to capitalize on that super efficient Webasto boiler to keep us nice and toasty no mater how cold it is outside. The day I was born in Whitehorse in the Canadian Yukon it was minus 53 degrees out so I know what Cold is!
BTW, at these temperatures you don’t really need to bother with Centigrade/Fahrenheit conversion as –40 C = –40F but if you want to be more precise, –53F = –47C which is more often known as simply k k k k K K K K K K KOLD!!!
OK, that wraps up the latest Möbius World Weekly Progress Update and I hope it helps provide some good reading and distraction for all of you who are similarly practicing some form of isolation as we all try to navigate our way through this most unexpected global storm. All of us over here hope that all of you out there are finding ways to to keep yourself, your family and friends safe, healthy and happy throughout.
As this photo attests the weather here in Antalya the past few weeks has been spectacular and very Spring like. Last Sunday Christine and I took a break to go for a nice Sunday drive along what is apparently called the “Gulf of Antalya” which is a crescent shaped coastline that runs approximately East/West with the majority of the city of Antalya stretched in thin strip along this coastline for over 30km.
We were not the only ones out enjoying this sunny Sunday and one of the parks we walked through had lots of colourful kites for sale with grinning children at the ends of balls of string and their kites flying high above us.
I’m writing this a week later on another equally as brilliant of a sunny Sunday and hopefully I can get this posted in time to go out and enjoy it more.
The warmer and sunnier weather seems to have a Spring in the step of everyone else on Team Möbius as well and as a result there is lots of progress to show you so let’s get started.
Uğur, Nihat and Okan had a very productive week applying their significant skills with aluminium to several projects and one of the most gratifying to see was the completion of the four Dorade Vent boxes on the Forepeak. The simple concept of Dorade Box Vents have been used on boats for a very long time as they provide a way to bring fresh air inside the boat in rainy weather or high seas while keeping all the water OUT side where it belongs.
The work this week was to mount the new Vetus Cowls on the AL Dorade Boxes, finish installing the shut off lids in the Standpipes and then weld the Dorade Boxes to the ForeDeck. You may recall previous posts showing the construction of the Dorade Boxes and here Nihat is creating the slots or “Scuppers” along the bottom edge that ensures any water that enters the Dorade Box flows out onto the deck and overboard. Uğur then takes over to mount the White/Red silicone Cowls to the tops of each Dorade Vent. The Cowls act as big air scoops to grab all the breezes blowing over the bow and direct them down into the Dorade Box and then down the Standpipe into the interior below.
Nice simple mounting system with these silicone Vetus cowls which use the Grey plastic threaded ring in the foreground which is bolted and sealed to the top of the Dorade Vent Box to provide the attachment for Grey threaded collar you see at the base of the Cowl.
A slight loosening of the collar allows the Cowl to be rotated to any angle you want or turned 180 degrees to face aft if there are larger waves bringing water onto the decks. Before welding the Dorade Boxes to the Foredeck, they needed to finish installing these threaded Standpipe Storm Lids. This drawing I created shows how these work by having a center threaded rod with a knob on the bottom you can turn by hand to lift or lower the round lid to open or completely seal off the Standpipe. The Standpipes and the internal radial support were welded in place several months ago and so this week they worked on building these Lid assemblies. For a bit of added sealing, there is a groove cut half way through the thick Black rubber gasket. We applied our KISS approach and just used double SS nuts with Loctite to attach the AL Lids and Knobs to the threaded SS rods rather than welding them just in case they ever needed to be removed. This is the end result with the Lid fully raised to let in the maximum amount of fresh air. Or fully closed and sealed off. The vast majority of the time we will leave these Lids fully open and only close them when heading into eXtremely severe seas when there might be the possibility of waves breaking over the bow and overwhelming the Dorade Boxes draining capacity. The Vetus Cowls have the option to be fully removed and replaced with solid discs that would seal them off but this would still leave the Standpipes open so we took the “belts & suspenders” approach and added these adjustable lids to enable us to fully seal off these vents.
Looking up inside one of the Standpipes from inside the Master Cabin you can see it is easy to reach up and turn the knob. This ability to close these Standpipes while you are INSIDE the boat was a big safety factor in our decision to go to the time and expense of adding this additional shut off capability. As with so many aspects of building the boat, all the time goes into the preparation leading up to the final installation so after several months of working on the various parts of these Dorade Boxes, Nihat and Uğur can at last weld them to the deck. A quick hit with the brass wire wheel cleans up the welds and work surfaces and the Dorade Boxes are all done. We’ll leave the Cowls off until we Launch to keep them out of the way as work continues on the ForeDeck and Bow areas. We used the same system of fully sealable lids on all the vent pipes coming into the interior in other places such as this plate which bolts to the ceiling above the Main Helm area. There is a large box or air plenum behind the Red slots in the Pilot House Roof overhang you see here This plate, standing on its end here, then bolts to the ceiling to form the bottom surface with these five vent pipes to direct fresh air into the Main Helm area. Work on Vent Boxes continued with Uğur and Nihat welding up these side covers which bolt in place on the inside vertical surfaces of …… ……. the two Extraction Air Wing Boxes on either side of the very Aft end of the Pilot House on the Aft Deck. You can see one off to the Right of the spiral staircase and the other on the far Left. The Vertical Milling machine made quick work of cutting all the slots and holes in these eXtraction vent cover plates and then ….. Uğur welded these boxes to the inside. A large axial fan will bolt to the top surface you see on top here and when turned on this fan pulls air out of the extraction pipes inside the Wing Box which run into the Corridor, and Guest Head/Bathroom below. Switching from venting to wiring, Uğur and Nihat also installed the penetrations through the Engine Room Enclosure walls for electrical cables to run through. The two in the upper Right in the photo above and center here, are for the AC wiring for lights and switches inside the ER. Once the wiring is all run these will be filled with special watertight caulking to keep the ER and the Workshop fully separated and WT. Diagonally opposite on the ER they welded in this similar penetration down on the aft Stbd/Right corner of the ER where all the high amp DC cables from the two 250A @ 28V alternators and carry up to 14kW over to the DC distribution box that will be mounted up above the Workbench on the Stbd/Right side of the hull walls. Finishing up with AL work for this week; Okan put the finishing touches to the hinged rack that will soon hold three of our 300Wp solar panels on the front roof area of the Pilot House. More on that once we start mounting the solar panels. Uğur welded the plates for the Paravane rigging winches to the bottom of the hinged Arch.
Most of Hilmi’s work this week was not very visible as he raced ahead of the interior installation teams to put in the wiring for things like the 120V, 220V, 12V and 24V receptacles spread throughout the boat.
But this quick peek into the Aft Electrical Distribution box off the Corridor by the Guest Cabin will give you an idea of what he has been up to. Hilmi has also been spending more and more time in the Workshop as he wires up the various system components which are mounted there.
This is the control box for the Watermaker Which is off to the Right here and some of the other AC & DC wires and cables leading to the area on the Left where the Workshop Distribution panel will mount.
Speaking of the Watermaker, Cihan was busy this past week doing more of the plumbing for it such as the foil covered high pressure lines you see here running from the Watermaker up to the four membranes on the ceiling. On the far Right side of the WM, near the WT door from the Swim Platform, Cihan has now got most of the plumbing in place for the Webasto BlueCool AirCon unit which has been moved out of the way for now.
To Red accumulator tank and the Supply/Return lines for the sea water cooling lines are in place and ready to be connected to the Chiller unit. Always a good sign for me to see that little red hose in the background as that’s where Cihan will attach an air line to pressurize and test the plumbing for leaks. And more good signs as we see the soapy solution being applied to the joints to see if there are any leaks. The system is left pressured overnight to see if it all holds, which it did. The IsoTherm Calorifier or Hot Water tank has most of its plumbing in place; Safety Valve bottom Right, Mixing Valve for In-Floor Heating lower Left, Mixing Valve for DHW upper Left. Two more lines bringing hot water to/from the Gardner and the Kabola diesel boiler still to be added to the White capped off fittings. Both pumps for the Domestic Water pressure fully plumbed and covered in protective bubble wrap.
MASTER HEAD & SHOWER:
Transitioning from Plumbing to Heads & Showers, the Composite Team has been busy glassing in the Master Head on the far Right and Shower on the Left. They use flat sheets they make in house for the large flat areas on the walls and then build molds for things like this corner box section that makes the transition from the walls to the ceiling. Rectangular cut outs on the Right are where the large 2 mirrored door Medicine Cabinet will be mounted and provide access to systems behind the wall.
Areas such as this Shower Seat are first laid up in molds in the Composite Shop and then brought onboard to be glued in place with resin. Faruk on the Left and Osama are extremely skilled at this and everything fits just right. Once they have the pieces affixed they start taping up the joints in preparation for filling them in.
Now they are busy building the molds for the large floor and ceiling pans and you should see those next week.
This wider shot helps to show how things are shaping up in the Master Cabin with the Shower in the center area and the Head behind it. Wardrobes and bureau of drawers lining the Stbd/Right hull and the wall beside our bed on the far Left here.
Şevki and Selim are now staring to put the Port/Left hull wall back together And prepping the ceiling with mounting blocks for …. the ceiling grids. Weight reduction cut outs marked ….. and cut out…… …… and attached. More excitement as some of the removable wall panels emerge from the Upholstery Shop!
The SuperSalon has been rather vacant of late with most of the cabinetry over in the Finishing Shop to be varnished. This is looking aft towards where the Galley will be in the Aft Left corner, stairs up to the WT door in/out of the SuperSalon from the Aft Deck, double Fridges go in the cabinet on the far Right and open hatch into the Basement in the bottom Right corner. But the tide is turning and finished cabinets are starting to flow onboard with their lustrous varnished surfaces all aglow. Double opposing door Fridges in the background and double drawer style Freezers in the Foreground. We, well OK me, is a bit maniacal about eXtremely well insulated Fridge and Freezer boxes so even though our Vitrifrigo units come with the latest and greatest insulation from the factory we are adding at least 50mm/2” more rigid foam insulation around all sides and the backs of all four units and 100mm/4” on the bottoms.
Omur has the Freezer cabinet upside down to put in the insulation in the bottom area before he mounts this to the floor in the background which has another 50mm/2” of insulation. Up front the Main Helm has been getting its own insulation, this time for acoustics. Header for the door into the Master Cabin is now fitted. As are details such as this transition piece where the upper rear corner of the Fridge cabinet meets up with the big thick SuperSalon glass windows.
Black conduit carries solar panel cables down from atop the SkyBridge roof to the Basement. Over in the Cabinetry Shop, Omur is also routing out the openings for the hidden hinges such as the one you can see on the far Right here. Laid down on its side for Omur to work on, this is the Galley Garage that sits atop the marble countertop. These are small versions of the hidden hinges we are using on the full size interior doors you saw last week and these smaller ones ensure the Galley Countertop Garage doors all open smooth as silk at a touch of your finger on the solid mechanical latches.
GUEST CABIN & SHIPS OFFICE:
Lots of work on ceilings this week and Okan is bringing the freshly epoxy coated ceiling grids for the Guest Cabin and Ship’s Office aboard.
Once the ceiling grids are in place in the Guest Cabin he won’t be able to do this so Okan is taking advantage of the last chance to pass the large ceiling grid panels down through what will soon be the Galley countertops. Sure enough, a couple of hours later the ceiling grid is in place in the Guest Cabin below and no more access from up above here. Omer, Muhammed and Okan soon have the ceiling grids all securely fastened and leveled in the Guest Cabin. Omer is meticulous and detailed so he is going around and sealing any small areas between the ceiling grid and the mounts to the AL frames above and making sure they are fully insulated so there is no thermal transfer. Next up, Omer turns his attention to installing the Ro$ewood door frame to the Guest Shower. The floor in the Showers are raised to provide enough room for well sloped drains and the In-Floor heating PEX tubing so ….. …….. the bottom door sill is higher than the other doors. Once all the parts of the door frame fit, they are glued in place. Hakan is conferring with Omer on some details with the Shower drains and you can see what a masterful job Omer has done with all the matching grain patterns which flow across all parts of the door frame. The door itself will be plate glass for added light and openness in the Shower and when walking in/out of the Guest Cabin on the far Left.
Let’s go upstairs to the Finishing Shop for a peek at what our Polyurethane wizards are up to;
We can’t let the Rosewood steal the show every week and these Beech shelves are more than up to that task.
Looks like a wizard of a different kind in the middle here? What do you see? The Beech you can see on the inside of this Galley cupboard alongside the stairs up to the Aft Deck, has to my happy eyes, a beautiful contrast with the darker tones of the Rosewood and then also matches up nicely with the Blonde islands that naturally emerge within the Rosewood in many areas. More of that creative contrast on display within this section of the Galley Countertop Garages. Even though this back panel that the 50” SmarTV mounts to, setting on its side here, will rarely be seen by most it will bring great joy to my heart every time I see it and just knowing it is there. This will soon be the top surface of the double Freezer cabinet but right now it is huddling in the back of the Finishing Shop with its brothers and sisters waiting to be carefully wrapped in bubble wrap while they await their final trip onto Möbius.
Mr. GEE our Gardner 6LXB Single Engine
I was able to get away from all my other boat building duties a bit more this week and all day yesterday (Sat) and got some time to move Mr. Gee further along.
This is a special cylinder honing tool I have had great success with in the past and I’m using it here to put the final just right 45 degree cross hatch pattern on all the cylinder walls.
If you look closely you can just make out the thin line where the new dry cylinder liner has been pressed into the cylinder black casting. After pressing them in place they are precisely machine bored to original factory diameter which enables the block to be returned to same as new condition. This cross hatching s a critical detail that ensures that not all the oil is scraped off by the piston rings on each stroke so that there is just the right amount of lubrication to reduce the friction and wear. The process goes relatively quickly and I soon have all six cylinders in good as new condition. Next I turned my attention to the major cast aluminium components such as the massive crankcase in the foreground, the cast ribbed oil pan in the far Right background and several smaller cast covers on the Left.
All these parts had all been sandblasted several months ago and I gave them a light coat of primer so I now gave all surfaces a thorough wet sanding to get them ready for final coat of primer. I taped off all the openings and hung up the two big AL castings that form the flywheel housing on the aft end of the Gardner.
I am using a special ultra high temperature primer that is good for up to 600 degree C/1112 F which is WAY hotter than needed but works well to stick to the aluminium which is notoriously difficult. A few hours later ……. once the fan had cleaned out the air …… …… you wouldn’t know that these castings have been in service for almost 50 years and they were all ready for their final colour coating to bring them to better than new condition.
Stay tuned, much more of Mr. Gee’s renovation to come in the following weeks.
Ending as we have been doing with the New Arrivals here at Naval Yachts things were much slower than the past few weeks but no less exciting for me as this load of thick wall 150mm / 6” OD AL pipe arrived.
Any guesses what this will soon become? Will it help you to show you that this is eXtremely robust pipe?
I’ll have much more details to show you in the coming weeks but this is for building the Davit system for bringing our Tender on/off the Aft Deck once Yigit has it fully developed in Rhino. Until then these quick renderings, thanks to Yigit, will have to tide you over.
And that’s what’s all of us on Team Möbius have been up to this first week of March 2020 over here at Naval Yachts in Antalya.
We REALLY appreciate you coming along with us on this adventure and please add any and all comments, suggestions and questions in the “Join the Discussion” box below.
First and foremost Christine and I, along with everyone on Team Möbius here at Naval Yachts, we want to wish all of you a VERY Happy New Year and the hopes that 2020 will be the best circumnavigation of the sun for all of us. It is shaping up to be a VERY good year for us as we all work relentlessly towards launching the very first XPM and our new home Möbius in the next few months.
While it does often remind me of that saying “when you are up to your neck in alligators, it is hard to remember you are there to drain the swamp”, this adventure continues to be an awemazing experience for us and very much remains a labour of love and combined work of art and engineering.
And while we gladly chose to use a “pay it forward” approach to this blog and do our best to openly share all aspects of turning our vision into the reality of the very best Goldilocks just right, just for us boat, we REALLY appreciate the thousands of you who chose to subscribe and join us on this grand adventure. It means a great deal to us and you add a huge value to the whole experience so a very heartfelt THANK YOU! going out to all of you as we get this new year and this new decade started.
Click to enlarge the photo to see the first of many New Year’s Eve kisses standing in front of our already beloved Möbius with some of the crates in front that are piling up as more and more new equipment arrives.
When you are married to your best friend and your Captain who also happens to be the most Beautiful person you know, you take EVERY chance you get to kiss her!
Naval Yachts sent everyone home at noon on New Year’s Eve and reopened on Jan 2nd so we all enjoyed a 3.5 day work week. Christine and I enjoyed the chance to have time together to engage in deeper discussions about the thousands of decisions needing to be made and new learning about such scintillating topics as NMEA 2000 network topologies so we spent much of our “time off” comfortably sitting in front of our large 50” monitor at home to have all our reference info easily displayed for both of us to see, point to and modify. Different strokes for different folks right and being the crazy couple we are, this was great fun for us.
In the foreground you can see that Christine is getting lots of help from Commodore Barney aka the Yorkshire Terror and if you click to enlarge and look closely on the couch behind Christine’s back you can just make out Ruby the Wonderdog who is also supervising her work.
New Year’s Day dawned with clear blue skies and sun to light up the mountains which surround us and showed off their freshly snow covered tops. Not what many people imagine when they think of Turkey but we love this country and even more so her people, food and sights. We are very anxious to move aboard Möbius and get back to life at sea but we will also miss this special place that has been our home based for over two years and our Goldilocks location to built our Goldilocks boat; just right, just for us. We did take a bit of time off on New Year’s Day to go for a long walk to some of our many favorite spots along the Med coastline that is only a few blocks away and a large newly constructed park along both sides of the new inlet they are putting in which will eventually have a large superyacht marina in the waters you can see here. If we were to have any regrets it would only be that we don’t get or take enough time to enjoy our incredible surroundings every day. This spot along a beachfront walk is at the very far West end of Antalya and only a few blocks from both our apartment and Naval Yachts in the Antalya Free Zone.
In the background you can see how the city of Antalya stretches along the crescent coastline to that point you can see in the distance in the upper middle of this photo.
All very beautiful and fun BUT even we couldn’t top the news the next day that Naval Yachts had expanded VERY significantly with the arrival of the very first girl in the Dinc family for several generations.
Meet the newest member of the Dinc family; Okyanus Ida, born Jan 02, 2020 at 2.65kg. Baby and Mom both doing great. Dad Baris, we’re not so sure?!
Welcome to this most awemazing world Okyanus Ida! Oh the places you will go and the Love you will know.
Well, I certainly can’t top that but let’s get back to boat building shall we?
I’ll start with a brief update on what the Sparkies or electricians have been up to this week and see if you can guess what Hilmi, our electrician seen here driving the forklift, is moving up onto the front deck of Möbius?
Hint, they are VERY heavy! Many of you will have guessed correctly that these are the two pallets full of our batteries. I know many of you have been patiently awaiting my Tech Talk discussing our new battery choice and the details of our whole DC system and I’m afraid I need to test your patience a bit longer as I just have not had the time to finish that article, but it should be done and posted within the next week or so. The not so well kept secret many of you have already figured out is that we changed the battery type we are using for both the 24V @ 1350Ah House Battery Banks and the Gardner Start Batteries from OPzV Gel type to Microcell Carbon Foam batteries by FireFly International.
This graphic which you’ve seen in previous posts will give you the high level view of the overall Electrical System on XPM78-01 and I’ll be doing a much deeper dive into these components in future posts. Back onboard, Nihat is working on the cross members for what we are calling “the Victron Wall” as it will soon have all the big blue Victron boxes mounted which include:
3 Multi-Plus 5kW 220V Inverter 120A Chargers
2 Multi-Plus 3kW 120V Inverter 70A Chargers
Centaur 90-265V 50/60Hz “World” 24V @ 60A charger
2 Orion DC-DC 24-12V @ 7A converters
14 100/30 MPPT Controllers
With apologies for the poor quality this photo of the sketch onboard will show you the basic layout for this wall and some of its components. The main high amp DC circuit distribution panel will be in the middle flanked by the Victron components.
The 14 MPPT Controllers will mount on the other side along with several other DC related equipment. One of the many advantages of building wtih aluminium and having this cavernous Basement area under the whole SuperSalon floor is that we can put in these “walls” anywhere we like to create an enormous amount of surface area for mounting equipment.
Having so much area means we can space the equipment out to make access eXtremely easy and in the case of heat producing components like these Victron units, keep them much better cooled.
The whole Basement is also fully ventilated wtih both passive and active fan assisted ventilation which is separate from the same level of ventilation in the integral Battery Boxes which you can see on the Right.
Just about done, Hilmi with his back to us helps hold in the flatbar cross member that will soon be home to some of the 14 MPPT controllers.
Cihan was moving too fast for me to catch up with this week I only caught him in this one shot to show you some of his latest handiwork with the plumbing on Möbius. This shot is taken inside the Engine Room looking at the forward Starboard/Right corner.
Here he is connecting one of the water supply hoses to fill the Starboard ER water tank. Intake Sea Chest is right behind him and you can see the white perforated tray running across the WT Bulkhead which will soon fill up with more water hoses.
Nogva CPP Servo Gearbox in the bottom Right and Mr. Gee our Gardner 6LXB will soon be bolted in front.
Evidence of Cihan’s work is also evident up in the Master and I think some of you will be quite interested to some of you how we are going to handle draining shower and floor in the Master Cabin so let’s take a look. We are going to try out this relatively new Whale Gulper IC drain pump system. With our floors sitting on top of all the integral fuel/water tanks it is challenging to be able to use gravity to drain the water from the floor of the shower and the Head and this Whale IC system is the perfect solution.
If you click to enlarge the photo (works on all photos BTW), you can see the diagrams showing how this works.
This model handles two drains by having each drain hose go straight into the round yellow 2 way manifold you see on the right. Inside is a small electronic water sensor which is the IC Intelligent Control in the name and when it senses water it sends the signal to the Gulper diaphragm pump on the left to turn on and pump the water out of the manifold and into either the Grey Water holding tank or Sea Chest. When there is no water in the manifold sensor it shuts the pump off.
Here is what the drain looks like mocked up on the floor in the Master Cabin Shower. There is a matching one off to the Right just out of this picture which will drain the floor in the adjoining Head/Bathroom. A hose will connect the Yellow manifold to the horizontal Grey fitting coming from the shower floor.
You can see the Yellow 2 way manifold hiding in the center background and on the Left atop the White S trap is where the drain in the shower floor will be. Floor height is raised in the Heads to provide enough drop to gravity feed the manifold. The pump will mount on the other side of the WT Bulkhead in the Forepeak so the drain will be completely silent.
All very simple and automatic compared to the more common marine solution of having to turn on a pump manually or building in a shower sump box with a float switch and centrifugal pump which typically clogs very easily and requires frequent maintenance. Music to my ears and one of the XPM theme songs; Low Maintenance!
Uğur, Okan and Nihat who is pictured here, continued where they left off last week putting in the grid for the removable Alucobond sheeting on the walls and ceilings of the Workshop and ER. You can see the aluminium L-bars in the aft most end of the Workshop are now in place and ready to receive the Alucobond sheets.
Nihat is also putting in some of the last bits of EPDM insulation foam on the Aft Transom wall where Cihan will soon be installing the two shelves for the Accu-Steer HPU400 Steering Pumps to mount directly overtop of the Rudder Post and Tiller Arm Head which sit right about where Nihat’s knee is.
Rotating about 90 degrees to the Left looking at the Starboard/Right side of the hull we see that the L-bar mounts are in place and ready for the Alucobond.
The Black/Yellow tool box and Blue bucket are setting atop the AL Workbench and cable trays on the ceiling and Port side wall are starting to fill up with electrical cable and plumbing. First two of the AlucoBond panels to be fitted along the Starboard/Right side of the ER and overtop the Day Tank. Sticks being used to hold the individual panels in place while they are being fitted. Sporting his fashionable New Year’s haircut, Uğur puts in the next panel Aft of the two above. Same story on the opposite Port/Left side looking Aft from the WT door from the Guest Cabin into the Workshop. The walls are next in the queue to have their Alucobond panels fitted. Pardon the poor focus but this is the system we will use to fasten all the Alucobond panels to the L-bar. Self drilling and tapping screws which have that special brass washer that is threaded on the outside circumference and the chrome cap is threaded on top. Looks like this all assembled and makes for a nice finished look.
Whenever I want to remove one of these panels to access what’s behind I just twist off the caps and undo the screws. KISS, Keep it Simple and Safe.
GUEST CABIN/OFFICE CABINETRY:
I tend to save the Cabinetry Team’s work for the end because otherwise their work with this Rosewood tends to steal the show and with doors like this make that quite easy to understand.
But now let’s go check in with Omer, Omur and Selim and see what’s new this week. Omer is in charge of the cabinetry in the Guest Cabin, Head, Shower and Corridor Office and we find him working on that “Swiss Door” we showed you last week when he was fitting it into place in the door frames onboard Möbius. Now he is trimming the solid edges with their radiused corners and rabbits/grooves for door seals. There are French Doors, Dutch Doors, Pocket Doors and so we’ve come up with this Swiss Door moniker for the two doors we’ve designed into the boat, one in the Guest Cabin and another in the Main Cabin. Both of ours are off the boat right now and this type of door is not well known but I was able to find this shot online that shows how they work. A single door which swings shut on two different doorways.
We figured these doors are a bit like a multi purpose Swiss Army knife and hence Swiss Door!
We had one on our former sailboat “Learnativity”, the source of a lot of ideas we are bringing with us onto Möbius. They eliminate one or more doors so a big weight savings and cleans up areas on the boat where you might have multiple doors all competing for space and swing room. More KISS
On Möbius here is what that door looks like looking out through the entranceway out of the Guest Cabin into the Corridor where my “Clean Workbench” office runs along the Port/Left hull. Swiss Door on the Right now closing off the Head/Bathroom, Shower on the Left. Door is hinged on the far side nearest the Corridor. Stepping out into the Corridor and looking forward to the stairs that lead up to the SuperSalon shows that same Swiss Door with its hinges about where the blue tape is. Your imagination shouldn’t have too much trouble seeing how it will swing open from here and shut against the door jamb in the foreground when our Guests would like some privacy or when Christine is working at her Office in there and wants to keep her pesky husband out! Back in the Cabinetry shop these are some of those door frames and door jambs ready to be glued up and finished. Laminated cores wrapped in Rosewood veneer and solid edges makes these both super strong and beautiful. Not that I’m biased or anything. Omer also worked on finishing up the Pullman Berth inside the Guest Cabin and for orientation here is a rough rendering of what the Guest Cabin looks like with the Pullman Berth hinging out of the Upper Right side of the back wall which runs along the Starboard/Right hull. It folds up to be out of the way as it is here and then easily folds down like Pullman Berths on trains and ships or a bit like a Murphy bed in homes. Here Omer is working on the single bed sized frame that folds down to make the Pullman Berth. Flipped over to show how the mattress will be fit inside this frame and stay secure as it is folded up and down. Before he glued it up, Omer took time to show this good example of how the biscuit joints work to create super strong glued joints.
But what are those five holes for??? Aha! Yunus, our Stainless Steel guru has whipped up these SS hinges for the Pullman. One mounted in the lower sides of the outer cabinet which the Pullman Berth frame sits inside of.
Vent grills on the top are where the cold/hot air will come into the Guest Cabin/Office. With the Pullman bed frame all glued up and sanded, Omer added these strips of Beech to provide that thin gap running inside the corner between the strips and the frame sides. This is where they will tuck the leather that wraps around the outer surfaces of the Pullman and are pulled tight. More on that in coming weeks as the interior finishes begin to be added.
GALLEY COUNTERTOP GARAGES:
Not to be outdone, Omur and Selim were also hard at work on the cabinetry for what we call the Galley Garages that set atop all the Turquoise granite countertops as you can see rendered here.
Dinette or Settee in the foreground with Galley behind on the Left side, entry door and stairs down from the Aft Deck on the far Right side blocked a bit by the tall twin fridge cabinets and Lounge on the far Right.
This overhead shot puts the whole SuperSalon into perspective. Stairs down from the Aft Deck and second set down to the Corridor and Guest Cabin in the bottom Right. Continuing counter clockwise; Lounge area with Eames chairs, Main Helm chair center Left, stairs down to Master Cabin upper Left, Dinette/Settee, Galley in upper Right corner with Garages wrapping around all the countertops.
Omur checking the fit of the Garage doors on the Garages that run along the Stbd/Right side windows as prepares for laminating the Rosewood veneer to finish these off. Same set of Garages seen from the back edges that will run along the 28 mm glass side Pilot House windows. The cut-out where his hand is are where the vertical aluminium I-beam frames and window mullions set. Selim has been busy similarly finishing off this set of Galley Garages that run along the seatback of the Dinette/Settee. The glue bottle will help give you a sense of size and scale of the interior. Same glue bottle inside this other set of Garages which run along the Aft windows to show how these interior volumes vary.
You can see how Selim and Omur have finished off all the solid Rosewood edging around each door frame and have carefully filled and sanded all the outer surfaces flat and smooth. All this is in preparation for the final step of applying the carefully matched Rosewood veneer to all these exterior surfaces. If you check out the shapes of these Garages in the renderings above and notice the mitred corners where each set meet and make the 90 degree turn, you can appreciate how much of an Origami like puzzle it is to figure out the shape of the single piece of Rosewood veneer needed to wrap around all these exterior surfaces.
Here is on Garage’s veneer all carefully selected and taped together ready to be laminated to the cabinet behind. But just how are they going to manage to glue this single sheet to all those surfaces keeping everything lined up and getting the veneer tightly squeezed against the cabinet surfaces?
Clues to the answer lie in the strips of black tubing you may have noticed in a few shots and this one on the left. And you will also note how the open end of this cabinet has all been stuffed full of foam? Hmmmm, more of that black tubing running around all the corners and edges ………. More clues here with this vacuum gauge…… Which is part of this big vacuum pump and what you see in the background answers the riddle.
Yup, they are going to vacuum bag all the Garages and glue the Rosewood veneer on in a similar way in which the new high tech composite fiber such as Kevlar are being laminated in their molds. Each cabinet takes it turn being wrapped up in this special vacuum forming plastic and you can now see the purpose of that black tubing…….. …………. and the foam is to keep the plastic sheeting tightly sealed as it goes around corners and the foam is to keep the plastic from being sucked inside any openings on the ends as they take the vacuum up to about 600mmHg. That’s a LOT of vacuum, and you can see evidence of that in this shot where the veneer spans one of those cut outs for the window mullions we saw earlier and notice how the veneer is being pulled down into the vacant space by the vacuum inside. Hakan is helping Omur to monitor the progress and keep everything sealed as they pull down more and more vacuum on this largest of the four Garage cabinets and use the internal vacuum to apply huge amount of evenly distributed pressure on the veneer to adhere it perfectly flat against the inner core of the cabinets. This shot looking down the full length of this cabinet the reflection helps show how well the vacuum pulls the veneer tight and flat against the underlying cabinet. The fully vacuum bagged cabinets are left for at least 8 hours for the glue to fully set and then the vacuum is released and the plastic pulled off.
Now they can remove all the black plastic tubing and foam. The overlapping veneer can now be easily trimmed off with a sharp knife and others are cleaned up with a hand router. Like the caterpillar that finally emerges from his cocoon and becomes the most beautiful butterfly our Garages emerge from their plastic cocoon to reveal THIS beauty! I had to touch it to make sure it was real. I could stare at this all day and this is the ROUGH out of the bag finish! And just wait till you see what these Garages look like once they are all joined together in the Galley sporting their swirling Rosewood grain all matched up. Omur showing us some of how that magic happens as he checks out the next pieced together sheet of matching Rosewood for the Garage which runs perpendicular to the long one on the ground to the left that we just watched emerge from its cocoon. Selim helps to carefully position the veneer in just the right spot which is marked off on the tape to register with a matching mark on its Garage cabinet as it gets ready to be vacuum bagged. A closeup of the long cabinet showing how the veneer and the solid edging match up. Next step is to radius all these corners with a 5mm router bit for that “quilted” look I so like and has been done throughout all the cabinetry on Möbius.
But WAIT! There’s MORE!!!!
Upstairs in the Finishing Shop, that team has started to apply the 5 coats of clear PU varnish to some of the cabinetry that has recently been finished so let’s finish off this week’s Progress Update with a peek in there. These are some of the cabinets from my Clean Workbench/Office in the Corridor we saw earlier. Check out how well the Rosewood contrasts with the inner Beech surfaces. Only 2 of the 5 coats of PU and already looking awesome to my eye. Here is the cabinet you may remember seeing a few weeks ago inside the Guest Cabin Head with the little White sink on top. Some might say why bother to finish off areas like this bottom of my Office cabinet with the groove for the indirect LED floor lightning strips when only a mouse would be able to see it?
Because I know it’s there and it makes me VERY happy knowing it. But I don’t think anyone will question why we are going to such lengths and expense to use Rosewood for all our interior when you see results like this starting to emerge. Mother Nature is as close as I come to religion which is a big part of why I am so filled with profound joy when I’m out at sea.
IMHO, she outdoes even her awemazing self with examples like this. Do your eyes and your soul a favor and click on this image, ideally on a very large and very good screen and join me as I just sit in awe as I stare at this perfectly flat surface that convincingly fools my eye into thinking it is a beautiful brown curtain being pulled back to reveal that creamy depth inside.
NOW you might understand why I refer to Möbius as a combined work of art and engineering. I can’t top Mother Nature so I will leave you here as I go back to stare at her latest magic.
Thanks for joining us again this first week of 2020 and year of the launch of XPM78-01 Möbius.
Lest you be wondering, I can assure you that Santa is alive and well in Turkey and as you’ll see in this week’s update, I have a preponderance of evidence to support this claim So many new things have shown up this past week I won’t be able to cover them all but I’ll show you most of them as well as the progress aboard Möbius this last week of 2019.
As we make the final push towards launching the first XPM the demands on all our time goes up so we don’t get too many days or hours doing anything but working on Möbius but Christine and I did stay home from Naval Yachts on Xmas Day and although we both spent the day working on XPM related things we treated ourselves to working on things that needed our simultaneous attention and so we spent a great deal of the day in comfy chairs we pulled up in front of a big 50” monitor so we could discuss and learn things together, which for us is great fun. We are usually so busy working independently, often with Christine at home and me at the shipyard that we only get our evenings to discuss and work on things together so it was a real treat to have the whole day to ourselves.
Well, mostly to ourselves, we did have more evidence of Santa’s present in that we also spent the day with two of his best elves.
If you click to enlarge this photo you’ll get a kick out of that little wood plaque that Christine picked up at a little market in our neighborhood. Even though “Iyi Seneler” is Turkish for Happy New Year, you can see that somehow Santa, Frosty and Rudolph the red-nosed reindeer are a big part of this time of year. I’ll keep you waiting till the end for all the other evidence of Santa so we can dive right into all the progress that all the other elves on Team Möbius accomplished.
You may recall seeing these two water manifolds which Cihan expertly put together using PPR/PVC fittings and ball valves a few weeks ago. This week Cihan welded in the vertical flat bars and mounted both manifolds along the Starboard/Right side hull that runs alongside the Engine Room Enclosure walls on the left here and just aft of the Day Tank mounted on the WT Bulkhead with the Guest Cabin on the other side.
You can also see that more and more of the AC and DC wiring is showing up in more and more areas and those white perforated cable trays are rapidly filling up.
Several of you have asked about the PPR pipe and fittings being used onboard and if it is the same as PVC. It is similar but PPR pipe is a Pipe made of Polypropylene Random Copolymer (Polypropylene Random Copolymer type 3 to be exact). The PPR pipes are very common throughout the world and are mainly designed for the distribution of hot and cold water which is what we are using them for aboard Möbius.
Unlike PVC which is most often glued, PPR is a thermal setting plastic so special heating tools are used to melt or weld fittings to the pipes for a very rapid and leak free joint. One other nice thing about the PPR fittings we are using is that they have SS threads moulded into the fittings such as this 90 degree elbow which makes
And some of you were also asking about the vibration dampening mounts we are using to mount equipment that doesn’t come with its own such as in this case the three green circulation pumps you can see in the background which move the hot water through each of the PEX tubes in each zone/cabin. These are simple generic mounts with a SS stud on each side with thick rubber vulcanized between the two. The rubber also keeps all the equipment electrically isolated so that we can be sure that all electrical current onboard only travels through the wires we install and there is no current flowing through the aluminium hull or other components.
The Dynamic Duo of Uğur & Nihat continued their relentless work on aluminium based projects not the least of which was finishing the installation of the prop tubes. Hiding under the protective wraps is the big Nogva CPP propeller as it waits for the installation of the Nogva Servo Gearbox in the Engine Room.
This shot also shows the shape of the prop tunnel which enables the prop to sit up higher and thus reduce our draft below the waterline to a mere 1.2m/4ft which is eXtremely shallow for boats of any size let alone one this large. This becomes a huge advantage for us because we can make it through shallow passes and often be the only boat that can make it inside tropical atolls or go up rivers and fjords that other boats can’t.
The other benefit of the prop tunnel is that we can keep the prop shaft and motor closer to level and not tilting down too much. The closer a prop shaft is to being parallel with the waterline the more efficient it is.
Last week you saw Nihat & Uğur start fabricating this door for the HazMat locker on the Port/Left side of the Swim Platform and this week they finished it and mounted it on its hinges. They are waiting for the dogs/latches to arrive and will install those with their handles so this door can be fully watertight.
This door is the only opening in the Hazmat locker so it s is fully sealed off from the rest of the boat enabling us to safely store flammable or hazardous materials such as diesel fuel, paint thinners and the like. Taking a break from welding fumes Uğur and Nihat turned to building the ceiling grid that will be used to mount the removable ceiling panels in the Workshop and Engine Room which are both subject to a lot dirt, dust and fumes over the years and I wanted them to have a tough, fireproof, light reflecting and easily cleaned surface. We are using Alucobond Plus for all the ceiling panels in the Workshop and to cover all the walls and ceiling in the Engine Room. Alucobond comes in plywood size sheets which is easily worked with carbide tipped woodworking tools such as table saws, routers, etc. and the outer aluminium surfaces are painted white and delivered covered with a protective peel-off foil that will be removed just before we launch and protect these surfaces in the meantime.
The more traditional wall and ceiling coverings in the Engine Rooms of most boats is aluminium sheets that are perforated with hundreds of small holes to help dampen sound a bit but I find them to be a real bear to clean after a few years accumulation of dust and oil in the air starts to fill all these pores.
Alucobond’s smooth flat white (in our case) surfaces are extremely easy to keep clean and reflect light well so visibility is much greater as well. They also add to the fire rating of the Engine Room so what’s not to like?! Okan pitched in as well to help align the aluminium L-bars which they are fastening to the ceilings and walls to provide smooth flat mounting surfaces for the Alucobond to be screwed to. These panels will also help protect the wiring and plumbing running across the ceiling but be easy to remove whenever I want to access these areas.
Mounting all the Alucobond is very time consuming so you will be seeing a lot of Alucobond in the coming weeks as all these panels are installed.
Speaking of the Engine Room, look who decided to pay his first visit there? None other than Mr. Nogva CPP Servo Gearbox. This shot is taken standing at the forward end of the large hatch in the Aft Deck between the two Vent Boxes and looking down into the aft end of the Engine Room. Moving to the other end of the hatch looking at the forward wall of the ER you can see where Mr. Gee will soon be living bolted up to the Nogva Gearbox., both of which will rest on mounting struts coming off the thick longitudinal AL engine beds. The two vertical pipes in each forward corner of the ER are Sea Chests; Exiting on the Left and Intake on the Right. Mr. Nogva is resting on a wood pallet spanning the two Engine Beds for now as the mounting struts have not been made yet but you can see how it will soon drop down from here to connect its output flange to that red flange on the end of the prop shaft on the far right. This is the input side of the Nogva and that round SAE1 bolt pattern will soon be bolted to the matching housing on the aft end of Mr. Gee our Gardner 6LXB engine. The beefy cogged black rubber disk is a Centamax flexible coupling that the flywheel of Mr. Gee will drive. We are using a slightly different model but this image shows how the three parts of a Centamax coupling fit together. The outer aluminium flange is what bolts to engine’s output flywheel and those inner aluminium fingers mesh tightly with the matching groves in the thick black rubber disk which is attached to the keyed flange in the center which transfers the torque and power to the input flange of the CPP Gearbox.
Centamax are eXtremely heavy duty flex couplings which significantly reduce any vibration or noise in the propulsion system and help keep everything running smooth and quiet.
The Cabinetry Team mostly worked in the Cabinet workshop this past week so let’s head over there and see what Omer, Selim and Omur are up to.
Two weeks ago, you may recall seeing this shot of the countertops being fitted into the Guest Cabin Head/Bathroom.
VacuFlush toilet will rest on the roughed in plywood platform you see on the floor, sink on the right and the upper walls will be covered with leather panels.
Once all this was fitting up to Omer’s high standards, this week he brought all the parts back to the cabinetry shop to do the final sanding and prep work to send them up to the finishing shop to be sprayed with multiple coats of clear protective Polyurethane varnish. The cupboard below the sink is also here to be finish sanded before being sent up to the spray painting booth for its coats of PU varnish. As is this bookshelf from my Office area. Moving on to other Rosewood parts for my “clean room” Office area outside the Guest Cabin, Omer is gluing up the solid Rosewood for my infamous “Blue Horizon Line” and hand hold moulding. Once the glue sets he runs these long strips of Rosewood through the shaper to create the inside radius corner where your fingers grab hold.
On the right is the beginning of one of our “Swiss Doors” as we call the doors which close against two door jambs 90 degrees to each other. There are French Doors, Dutch Doors so we thought we would call these doors which do double duty in a kind of “Swiss Army knife way” Swiss Doors. Here is how they work. In the case of this door, in the position in this render it closes off the the Guest Cabin Head/Bathroom.
Note: that for clarity in this rendering I have removed the Shower that normally sits where this camera view is taken from.
My Clean Room workbench/office is on the left and stairs up to the SuperSalon in the center. Now you are sitting atop that workbench above and looking across to the Starboard/Right side and into the Guest Cabin with the Head behind the wall on the Left side and the Shower behind the wall on the Right. Door hinge is on the Left side so when the door is swung open from closing off the Head, it closes against this Cabin entryway and gives privacy when heading in/out of the shower or whenever else wanted.
Simple, elegant and allowed us to eliminate two other doors in this area alone.
A bit later, that same door, now flipped over with its solid Rosewood edging being applied. These interior doors are foam cored and built from the new super lightweight Poplar marine plywood which is helps our weight saving budget tremendously.
Lower portion of the door on the Left will be covered wtih Rosewood veneer seen on the right.
The upper framed area will have a leather panel inserted to match all the upper wall surfaces above the Horizon Line running throughout the boat.
Last week we saw Omur and Selim start building the liners for inside surfaces of all the aluminium hatches we designed and built in house here at Naval Yachts. Several of you asked about how the lamination process worked so here are a series of shots to answer those questions.
As we saw last week, Omur and Selim laid up the initial shape and size using the hatches themselves to form the first few layers.
Once the glue had set they slide the inner lining out of the hatch and bring them back to the workshop to start laying in the next round of laminations which provide the base for the Rosewood solid edges and top lamination.
Omur starts by fitting the next layer. The material being used for the laminations is a special type of thin and easily formed wood which is itself a series of laminations. With the next lamination piece ready Omur spreads and even layer of waterproof marine PU glue on all the surfaces. Sets the lamination in place with the end against the block he has previously temporarily tacked in place to match the length of the lamination strips. A scrap bit of plywood with a radiused corner is set in place to help apply even pressure when the lamination is clamped and also push the lamination fully into the radiused corner. Clamps in both directions press the lamination tightly against the hatch liner. More clamps are added to apply pressure all along the lamination and it is left to cure before the next lamination is applied. Rinse and repeat to make all ten of these hatch liners. While Hatch Liners dry, Omur and Selim move over to the countertop Galley Garages now that they have all been fitted onboard Möbius. First all edges receive their solid Rosewood strips. Selim on the Left and Omur clean up and sand the insides of all these Garage interiors and start fitting the doors. Each door will have a gas spring cylinder inside so that when you press the locking latch that will be on the lower center of each door, it automatically opens fully and is held there till you push it back and it is locked in the close position. All latches onboard for doors and drawers are high strength positive mechanical latches so they cannot suddenly open in rough seas even if heavy contents inside were to come loose and fall against the doors.
Captain Christine, aka my Beautiful Bride, admires and inspects Ömür’s work on her Galley Garages. Back onboard Möbius the window sills along the Stbd/Right hull are now being fitted. This one is the back of the Settee with the Galley being on the far Right.
Same area looking along the other Settee back with the Galley and one of the Garages on the far Right.
One more perspective of the Settee looking at the armrest end that ensures you can’t slide off the Settee down into the steps to the Master Cabin.
As you can see there is voluminous storage everywhere you look. And that pretty much covers all the progress this last week of 2019!
But WAIT!!! I promised you more of the preponderance of evidence that Santa is alive and well in Antalya Turkey now didn’t I? Well, there you go………………..
First of the many new arrivals at Naval Yachts shipyard this week is this crate apparently full of fragile items.
Any guesses? It might be a bit confusing if you remember some of this same gorgeous Turquoise Turkish granite arriving last month but you are correct this is more pieces from that same block. There were a few problems with the first shipment having some cracks and poor colorations so Yesim contacted the stone quarry and they agreed to send us new replacement pieces. You will have to wait a few more weeks to see what these look like installed in the Galley but here is a sneak peek at one piece. And this overhead render which Yesim created using a photo of the actual granite to create the surface mapped onto the countertops will give you a bit better sense of how fabulous this will look once installed along with the finished Rosewood cabinetry. What? You want more?
Well OK then. Mrs. Santa, resplendent in her Vancouver sweatshirt and Starbucks Holiday latte in hand is about to inspect the next pallet full of exciting new equipment, this as you can see being from Webasto. This pallet, there are more to come, is filled with the components for the Air Conditioning and Heating system. This Webasto BlueCool V-50 Chiller at the center of this HVAC Heating Ventilation and Air Conditioning system and will be located out of the way in the Workshop.
This V-50 feeds either cold/chilled or hot water to …….. …… one or all of the four of these BlueCool A-Series air handlers located in the Cabins and SuperSalon. There is a 12,000 BTU air handler in the Master Cabin, one in the Guest Cabin and then one 12,00 and one 18,000BTU on either side of the SuperSalon. We chose this system for its versatility, robustness and quiet. The Air Handlers are relatively small so they can be easily tucked behind the cabinetry in these living spaces and use ducting to direct the cold or hot air to the different diffusers located within each room. When the tropical temps and humidity become too high the chiller sends cold water to one or more of the air handlers where it circulates through a radiator with a fan blowing across it cooling the air as it enters the room.
In colder climes we have two options to keep things nice and toasty inside using this same V-Cool system. If the air and water temperatures are not too low the chiller can be run in reverse to extract heat energy from the surrounding seawater and use it to heat the fresh water inside the pipes running to each air handler. With hot water now flowing through the radiators the exiting hot air warms up the room.
More likely though, if we wanted to use the Chiller to heat the boat’s air we would more likely use the second option which is much more efficient than the reverse cycle method described above and when the seawater temps are below about 10C. Instead of using the Chiller to extract the heat energy from the seawater, we send some of our DHW Domestic Hot Water to the BlueCool Chiller and circulate this hot water to the air handlers to heat the air in each room.
The Kabola Ecoline Combi KB45 is our primary source of hot water and with a rating of 94% efficiency, low energy consumption and 100% soot free it is eXtremely efficient at heating our water onboard so this will be the most likely source of hot water we would supply the Chiller with. All our DHW comes from our Webasto/Indel Istotemp Calorifiers which provide us with three ways of heating the 75L / 20USG of water it holds:
Kabola diesel boiler
Gardner engine (when running)
220V AC heating element
The first two options heat the water in the Calorifier by circulating their hot water through coils of copper tubing inside the Calorifier and the 220V immersion heater heats the water directly with its heating element. Having these three independent sources to heat our water enables us to chose the most efficient source in any given situation. Whenever Mr. Gee is running we get to use some of the heat he produces to heat our water for “free” and then when anchored the super efficient Kabola kicks in to keep us with as much hot water as we need for either showering, washing or heating. On those rare occasions when we are plugged into shore power we can use that typically very cheap and efficient method of heating our water.
When it comes to keeping us all warm and toasty when we are in colder locations however, the coup de grâce will be our in–floor heating system, the beginning of which you have been seeing installed in the past few weeks. Those of you who have experienced living with in-floor heated homes know that they create THE most comfortable living spaces and we will now have that same luxury aboard Möbius no matter how cold it gets outside. Stay tuned here for more as Team Möbius gets busy installing all this HVAC equipment.
But wait! There’s Morrrrrrrrre!!!!!!!!!!!!!!!
Not content with just the pallet full of Webasto equipment, Mrs. Santa just had to tear into this other new arrival yesterday. A double pallet full from our favorite US supplier Defender Industries where we get the vast majority of equipment we source from the USA.
Such as you say? Well, glad you asked!
All our Furuno marine electronics and navigation equipment. I will cover this in MUCH more detail in the coming weeks of 2020 but a short list of our Furuno gear includes:
Furuno FAR-1523 BB Radar
with this XN13A 6ft Open Array antenna
Furuno SC-33 satellite compass for eXtremely precise heading information for all our other navigation devices such as …. our two NavPilot 711C Auto Pilots. Given the kind of passages we are on Auto Pilot becomes a critical bit of kit so we have two completely independent 711C systems onboard which we can switch between at any time. Just as important as knowing what is around us and steering us on safe courses is knowing what is below us and on the bottom of where we are considering anchoring so we also have a bottom discriminating depth sounder
On an even larger scale, we live and sail by the weather so knowing everything we can about weather is also critical information for us and we have this Furuno/Airmar 220WX Weather Station.
In addition to critical weather based information such as wind direction and velocity, air temp, humidity, etc. this solid state (no moving parts) instrument also has a killer 3 axis compass, rate gyro and axis accelerometer which is the technical way of saying it provides us with another source of spot on heading information no matter how much the boat is pitching, rolling and yawing, often through every one of the six degrees of motion! I put this on our previous sailboat and even up atop a 70+ foot mast the heading data was rock solid which is a huge determining factor in our AutoPilot efficiency and effectiveness.
Lots of other Furuno gear in these boxes which you will be seeing and reading about as they get installed including a very cool ultrasonic water speed transducer which like the 220WX Weather Station above has ZERO moving parts which provides MUCH better longevity and low maintenance. Some of you fellow passage makers and sailors might be wondering why there is no mention of a Furuno TZT2 MFD Multi Function Device or Chart plotter and that is because we are going with an all PC based navigation system on Möbius. I will elaborate on all the details of this decision in coming posts and the short version is that we feel this gives us much more flexibility and control over our navigation system and lets us upgrade to things like new graphics cards, processors, added memory and so on.
Our House/Boat computer enables us to do everything and more that a dedicated MFD can with while being more flexible and future proof and with much more bang for our rapidly diminishing bucks! Captain Christine and son Tim have built a wickedly powerful “boat computer” last month and we brought back with us and have been running here at the house getting it all setup and loaded with software the most important of which might be one of our TimeZero v4 Pro licenses which is what the screen shot above is showing.
You might think that Furuno was the only thing that Santa packed into this pallet full of boxes from Defender, but you’d be wrong. He also included many other equally important bits of kit such as all our many Maretron black boxes and senders which monitor and control most of the systems onboard.
Our Maretron system, with additional input via our NMEA 2000/N2K network of other equipment, enable us to create custom built screens such as this example above which if you click to enlarge will give you a good idea of some of the systems we monitor, alarms and rules we program such that we know what’s working, how well its working and are alerted immediately when they are not. While we absolutely LOVE being at sea and seeing the world this way, we need to be eXtremely well connected to our boat and what’s going on all around us as our lives quite literally and directly depend on this.
BTW, the Maretron N2KView screen shot above is thanks to a pair of our many mentors and favorite teachers out there, James and Jennifer Hamilton aboard their Nordhaven 52 mv Dirona. If you have not done so previously or it’s been awhile, do spend some time on their awemazing site to learn as we do from all their travels around the world. A truly mind boggling collection of eXtremely valuable information, learning and adventure.
Rounding up just a few more of Santa’s gifts he also brought us some of our many different communications equipment such as this Standard Horizon GX6000 VHF with RAM4 remote microphones along with an integrated AIS Class B receiver. This amazing device also manages to include a loud hailer with pre-programmed fog signals, GPS compass and DSC Direct Station Calling.
The Class B AIS receiver in the GX6000 above will be backup to our primary em-Trak Class A transceiver to ensure that we are seen by other ships out there, especially the big guys, and that we are equally able to know they are where they are and can contact them directly at the push of a button.
We had an em-trak AIS and this same multi talented Standard Horizon GX6000 VHF on our last boat and it was rock solid so we are sticking with what we know works and also have its little brother the GX1850G 25W VHF for the Tender. We chose this smaller GX1850G VHF above which does not have AIS because on the Tender we wanted a full transponder AIS so we now have a Vesper XB600 which gives us a great AIS to know what other ships are around us when we are out on the Tender and that the Mother Möbius also knows exactly where the Tender is when one of us or guests are out exploring on the Tender.
OK, there was still much more inside all those boxes from Defender but that’s enough to give you a good idea of the bountiful booty which the overly generous Santa brought us and I think meets my promise of showing you a preponderance of evidence that Santa is indeed live and well here in Turkey too!. Apparently we must have been a VERY VERY good little boy and girl this year, or at least managed to get Santa to think so.
Both Christine and I hope that all of you were equally good this year and that Santa showered you and your family and friends with a similar excess of evidence of just how good you boys and girls were this year. My next update will be the end of the first week and month and decade of 2020 so we both want to wish ALL of you the very best New Year and we hope that a year from now you will be able to say that 2020 was one of THE best years yet for you.
Happy New Year from the crew of Möbius and everyone at Naval Yachts. See you next year!
Say it isn’t so?!! We’re heading into the last week of the year? How the heck did THAT happen so fast??
In my naïve youth I used to think that time would slow down as you got older and especially when you “retired” but I’ve never been busier in my life and time has never whizzed by faster. I think that the reality is that time is one of the few constants in life and doesn’t care how old we are, how busy we are, how much we need to get done, it just ticks away like some rock solid metronome one second at a time. Back in 2009 I recall a similar year end experience in what was then my second year of single handed sailing around the world in my former sailboat sv Learnativity, where I was recalling all the different experiences I had been through in the past two years and not being able to believe it was possible that ALL that could have happened in just two years. Drove me crazy for a week as I was sure that somehow my “math” was wrong because it MUST have been more like fife years. But nope, it was just two. Over time, hehehe, I came up with the notion of Learning/Living Density or simply Experiential Density and that is perhaps the variable; same amount of seconds in the year, just varying amount of experiences, learning and living for each of us. Whatever the case 2019 has been a year VERY densely packed full of awemazing experiences and learning for Christine and I and I would hope that is the case for all of you as well. But enough philosophising and let’s get busy reviewing the density of experiences building Möbius this past week of December 16-21, 2019
As per part of the title there was some eXciting progress with on the Steering related equipment on XPM78-01 this week as well as many other systems and I’ll take you through all of those as well, however steering is perhaps THE most important system on any boat and especially on a power boat and eXceptionally so on an XPM given the eXtremely remote locations we and other eXtreme Passage Maker type boats tend to roam. On a sailboat if you were to lose all your steering such as having your rudder fall off then it is relatively easy to steer the boat using the sails. Ask me how I know! However with no sails if we were to ever somehow loose ALL steering capability on Möbius about the only option we would have would be to use one or our drogues or other warps you can fashion from long knotted or weighted lines and drag them off the Swim Platform and change the direction of the boat by moving the attachment point from side to side. All that being a VERY Waynewinded way of saying that we take the Steering System on the XPM’s VERY seriously. Uğur will help give you a better sense of size and scale of the rudder so you can see that it is both eXtremely strong and eXtremely big.
The other photos above show the rudder in various stages of construction and it is now all complete and ready to be installed so let’s go check out this week’s progress. These are the pair of self aligning PETP roller bearings which I worked closely with Thor Christen Hermann. the Systems Designer at Jefa Rudder Bearings in Greve Denmark to get them just right. Thor and everyone at Jefa was fabulous to work with and I can recommend them highly for any of your rudder related needs.
In the photo above the bearing on the left is the top bearing, lower on the right and the white ring in the middle is a thrust bearing to deal with any vertical forces and the black ring is anodized aluminium lock ring that is secured to the Rudder Post with locking setscrews. This section view from Jefa clearly shows how these bearings are mounted inside the yellow coloured rudder tube which is an integral component welded into the hull’s framing. A closer look at the lower bearing lets us see the black rollers for the 127mm/5’” aluminium Rudder post to smoothly glide on and down by my thumb you can see how the white inner race with these rollers inside, rotates inside the white spherical outer race which is fasted into the top and bottom of the Rudder Tube as seen above.
Next up, the 200mm/8” thick walled aluminium Rudder Tube is tacked in place after being precisely positioned with laser levels such that it is perfectly aligned in all directions and exactly on the centerline of the hull.
Let’s go see where those beautiful tendrils of smoke are coming from?
Aha! Now that Uğur and Nihat have tacked the Rudder Tube into position and also tacked on the additional 25mm/1” thick support braces, everything can be fully welded into the hull. This is one of the last major welding jobs to be completed and only leaves the installation of the Nogva CPP propeller and shaft to literally float our boat in the sense that she will be fully watertight.
Naval is using the latest Pulse MIG welders and in photos like this one you can actually see the pulses refracting the light which I thought was cool. Good comparative shot of the tack welds and the fully finished welds around the circumference of the Rudder Post where it exits out the top of the curved 15mm/ 5/8” plate of the Prop Tunnel. That same area now fully welded on the inside …. … bottom of the Rudder Tube fully welded on the outside….. … and top of the Rudder Tube fully welded to the Rudder Shelf inside the very aft end of the Workshop area. Door on the left puts you out on the Swim Platform.
Once everything cooled down the Jefa Rudder Bearings could be test fit into the Rudder Tube and we are looking up from under the boat to see the bottom Rudder Bearing here.
Next step will be to pump a special adhesive through a hole drilled through the side of the Rudder Tube and out a hole in the other side to fill up the special groves in the outer white bearing race and solidly affix the outer bearing to the Rudder Tube. OK, we’ve got a Rudder, we’ve got a Rudder Tube and Rudder Bearings, but how do we TURN the Rudder?
Oh right! The Tiller Arm I designed and has now been fully machined and fresh off the table of the CNC milling machine over at Tasot. If you’ve been following these weekly progress updates recently you’ll recall seeing this at huge block of aluminium being machined into the finished beauty you see here. I walked over to Tasot a few days ago with my rolling cart and brought this work of art and engineering over to Naval to test fit it to the Rudder Post.
Easy to see how these two halves will be clamped to the top of the Rudder Post with four long M16 bolts running through the four holes in the wings of the body of the Tiller Arm. These hardened and precision ground 25mm/1” OD pins are a close sliding fit into the Tiller Arm. Providing a super strong axis for the Heim joint ends of the two big Kobelt hydraulic steering cylinders we will see shortly below. Locking nuts threaded onto the ends of these pins will hold them in place. Back at Naval now for the first test fit. I have implicit trust in 3D models and the precision of CNC machining but we didn’t take the Rudder over to Tasot while the Tiller Arm was being machined so it was a great feeling to set this half onto the Rudder Post and have it fit perfectly! And of course the other half fit just right too.
Note the 18mm wide keyway cut into the top of the Rudder Post and in the photo above you can see the matching keyway cut into the Tiller Arm body.
The large through hole at the top of the Rudder Post is also part of the Steering System, the very end of the chain of redundancy and backups. There is a 70mm/2 3/4” OD thick walled aluminium pipe that is 2m/6.5′ long that can be inserted into this hole in the top of the Rudder Post and be used as an Emergency Steering Tiller. At the other end of this Emergency There are attachment points for block and tackle lines to run from the end of this Tiller to the hull frames on each side which would be used to lock the Tiller pipe in any location and move it as needed to steer. Obviously a bit of kit we hope to never use, though we will test on sea trials, but all part of the “belt and suspenders” approach we take for Steering and throughout the whole boat which enables us to be “Ready for the Unexpected”.
Continuing with this “knee bone connected to the thigh bone” and connecting the dots of the Steering System components, we now need to connect the Tiller Arm to the Kobelt hydraulic cylinders and that is what this next bit of Steering beauty is for. The bronze part in my hand is technically referred to as a Heim joint which is a spherical ball and socket type of joint which transfers the force from the Steering Cylinder to the Tiller Arm.
Kobelt equipment is eXtremely robust with their two favorite materials being bronze and stainless steel which you will be seeing a LOT of in the coming weeks as we get all the Kobelt equipment installed. With this Heim joint you can see how it is built to last for thousands of hours at sea with very little maintenance. A quick squirt of grease in that Zerk fitting to ensure these spherical SS ball and bronze socket are well lubricated and don’t wear is about all that should be needed throughout the long lifetime of these critical joints. OK, so now the Heim joint connects to ………???
This next example of the result when art meets engineering are these Kobelt 76mm/3” ID 7018 Hydraulic Steering Cylinders. The mounting base is where the cylinder is through bolted to thick pads on the Rudder Shelf you saw earlier. This is another SS/Bronze spherical joint the same as the Heim joint at the other end just encapsulated in this cast bronze base and again a simple Zerk fitting to keep this joint well lubricated, friction free and long lasting. And the Heim joint threads onto the other end of the SS shaft Steering Cylinder tom complete the Steering System’s connection to the Tiller Arm. But wait! What causes those big beefy hydraulic cylinders to move in and out you might ask, and I’m so glad you did.
Because I get to show you the final entry into this week’s Art & Engineering Beauty pageant, these Kobelt/Accu-Steer HPU400 Hydraulic Power Units. The anodized blue assembly on the right end is the very powerful hydraulic pump and the white cylinder under my hand is the 24V motor that drives the pump. There are two of these two speed pumps, one for each cylinder and we designed these with Kobelt engineers such that one pump and one cylinder exceed the steering requirements under the most severe conditions. Most of the time we will run them this way, one pump/one cylinder and alternate between the two every day or two when we are on multi week passages so we know they are both working and to keep them balanced for wear and use. If conditions were severe we can chose to run both pumps and both cylinders at the same time for even more power. In situations such as close quarter maneuvering such as docking in tight spaces, we can switch the pumps to their high speed and cut our 45 degree lock to lock time, 90 degrees total, in half.
Stay tuned for upcoming episodes where we are installing these pumps.
Some of which Cihan (right) and Okan already got started on this week as well. They are busy making the two AL shelves to mount the two Accu-Steer HPU400 suspended above the Tiller Arm in the aft end of the Workshop. The shelves have flat bar edges so that any spills of hydraulic oil over time are contained and easy to spot as well as easy to clean up. The three L-bar pieces tacked in place are for the six SS and rubber isolation mounts that secure the HPU pumps in place and keep them running silently. Next week you’ll see these shelves being mounted.
Whew! And that only gets us through this week’s work on just the Steering System so let’s move on to the next area of progress; plumbing!
We’ll stay with the multi-talented team of Cihan and Okan as they work on more of their plumbing jobs down in the Basement. While they were in the fabricating mood and tools they built this support rack for the Potable/Drinking Water tank. This poly tank is another example of the “Readiness for the Unexpected” approach in that it will hold 210L / 55 USG of fresh water that will be kept independent of the rest of the boat’s water tanks and domestic water systems. It will be plumbed to an independent water pump and connected to a second faucet at the Galley sink.
The only potable water we allow onboard is what comes out of our 200L/52USG per hour watermaker, never any shore side water so we know the quality of the water is the highest, being essentially pure H2O. However, there is always the chance, however remote, that the water in the six integral aluminium hull tanks could get contaminated or even more unlikely could escape. So this tank with its own pump and filtration system will always be at the ready just in case the unexpected should happen.
The white unit on the right is the Vacuum Generator for the Guest Cabin VacuFlush toilet.
Above the VacuFlush Vacuum Generator is this manifold which controls the hot water flowing to the three zones of the in-floor heating in each Cabin. Cihan has done his usual masterful job of installing these manifolds and picking up where we left off last week. Domestic Hot Water DHW from the IsoTherm Calorifier flows into the red handled shiny SS upper Supply manifold and then out the three fittings with the red flow meters on top.
Zone 1’s gray PVC/Red handle ball valve is dry fitted in the center to help determine the location of the circulation pump mounts which are the two aluminium L-bar pads on the right. Zone 2’s pump will mount on the pads you can just see at the bottom right and more fully in the photo below.
After circulating through the 15mm PEX tubing embedded in the floors in each zone, the slightly cooler water flows into the bottom of the polished SS Return manifold through the 3 SS threaded fittings below the 3 white flow control valves and returns the water back to the Calorifier via the black insulated PPR pipe with the blue handled SS ball valve.
There is a temperature gauge on both the Supply and Return lines to make it easy to see the temperature differential and performance of the system. The vertical SS units on the left ends of each manifold are for draining/filling the system and for bleeding off any entrapped air.
These are the AL brackets which Cihan has come up with for mounting each of the three speed Zone Circulation Pumps to the bulkhead. Here is the completed bracket test fitted to one of these pumps. Longer bolts will be used with an additional nut on each end to keep the clamping of the pump’s sealing flange independent of the mounting nut. Each one of these pump mounts will be bolted to those pads you saw in the photos above with rubber noise isolation separating the mounting bracket from the pads and keeping noise and vibration locked up in the Basement.
NOGVA CPP PROP & SHAFT
Well, let’s give Cihan and Okan a bit of a rest and move on to the ever busy Aluminium team of Nihat and Uğur.
After spending the weekend in the freezer to shrink, the orange coloured Cutlass bearing was pressed into the outboard end of the Nogva Prop Log Tube you saw being installed last week. The groves in the upper half ensure that water flows freely out of the tube and provides a steady supply of clean water to lubricate the prop shaft. When rotating the prop shaft “floats” on a thin film of water so that the Cutlass Bearing material and the prop shaft only touch when the prop is not moving.
That all set the stage for the Nogva CPP Controllable Pitch Propeller to be test fit. The smaller diameter end of the CPP prop hub at the bottom here is what fits inside the machined AL housing you see in the photo above. The stepped flange slides in about half way 20mm/3/4” into the AL housing and acts as a rope guard when, never if, you happen to snag a lobster pot, fish net or other underwater debris. At the opposite inboard end of the CPP Prop Shaft is the push/pull rod that runs inside the hollow prop shaft all the way from this threaded end to inside the bronze CPP prop hub. As this rod is moved fore/aft by hydraulic pressure inside the Nogva CPP servo gearbox the bottom end of each of the four prop blades is rotated in synch to change the pitch from zero to full forward or full reverse. Okan then gave the whole prop and shaft a thorough cleaning and a small army of men picked up the eXtremely heavy prop/shaft assembly and carefully slid it through the Cutlass Bearing until that stepped bronze end of the prop hub was the correct 20mm inside and attention can now turn to positioning the mounting brackets for the Nogva CPP Servo Gearbox inside the Engine Room and which we will pick up on in next week’s installment.
Speaking of the Engine Room, Nihat and Uğur were busy in there as well this week. With that clue can you guess what they were working on based on this photo? Full marks to those of you who guessed Sea Chests! These are located at the very front end of the Engine Room with the larger Supply Sea Chest on the right and Exit on the left. There will soon be two Vetus strainers flange mounted to the two pipes coming out of the Supply Sea Chest which will then both feed a sea water supply manifold for consumers such as the Water Maker, Gardner heat exchangers for cooling engine oil and coolant as well as the Nogva heat exchanger and then exiting into the wet exhaust system.
The 25mm/1” thick Engine/CPP beds are the flat sloped surfaces running top to bottom in this photo, water tanks on either side of them with their respective access ports bolted in place and SAE flanges around them for tank gauge senders and fill/supply lines. Engine Room diaphragm Bilge Pumps can be seen on either side of the WT Bulkhead with the Guest Cabin/Office on the other side.
Not easy to get the MIG gun all the way down here but the welder did a great job of getting a full set of deeply penetrating welds around the circumference of this Supply Sea Chest.
Yet another exciting bit of progress was Nihat (left) and Uğur getting started on the frames for all the WT Doors! They started with this door on the Port/Left side of the Swim Platform that provides access to the HazMat where we can safely store any Hazardous Materials such as diesel, paints, thinners, etc.. This one door they will build entirely in house here at Naval and the others will be high end WT fully certified WT doors from Bofor.
Here they are fabricating and tacking in place the inner flanges for the HazMat door frame. Which they complete very quickly, With the exact sizes of the frame now set, they moved on to fabricating the HazMat door. And had that knocked out just as quickly. Next week they will fabricate and mount the hinges and seals. Sliding over to the opposite Stbd/Right side of the Swim Platform they tacked the inner frame flange for the Bofor WT door. These doors will be bolted in place with industrial adhesive in between to seal completely.
Bofor is custom building all the WT doors for Möbius to our specifications but will look similar to this one. To be fully WT certified there will be two dogs/locks at the top/bottom rather than one as you see here and our doors will be left unpainted AL to match the rest of the boat.
The WT off the Aft Deck into the SuperSalon will have a full length window whereas the one on into the Workshop and the one between the Guest Cabin/Workshop will have a single window like the example here. With the mounting flange tacked in place, Nihat trims it to final opening size for the Bofor door frame to set into. Cihan clowning it up to show how the door frame and flange look from inside the Workshop. The Accu-Steer pumps and Tiller Arm you saw earlier in this post are sitting off to the right of this photo. And before you know it the frame flange is fully welded in place and ready to have these corner welds cleaned up and radiused.
More beauty to be found inside of Möbius this week as always. Omur, Selim and Omer often get to steal the show as their expertise and craftsmanship really shines as they work with the rich grain patterns of the Rosewood. This corner where the lower Freezer cabinet meets the taller Fridge cabinet is but the latest of many examples of their attention to detail with things such as matching the grain patterns to perfection. Stepping back a bit from that same intersection to show how the grain swirls forward onto the wall cabinet for the 50” monitor on the Port side of the SuperSalon and Main Helm. A few more steps back to show how the wall has been recessed for that large monitor. It will be on a HD swiveling mount which allows us to pull it all the way out of the cabinet, swivel it forward and aft and tilt it up down. This enables us to use this screen for both entertainment viewing of movies and photos from either the Lounge chairs or the Settee for our “dinner and a movie” nights and then quickly reposition it for ideal viewing from the Helm Chair when underway. Yet another example of Ömür’s creativity and craftsmanship are these little cut outs so you can easily slide your fingers round the back of the monitor to pull it out.
Over in the Cabinetry Workshop with his compact sold edge router in hand, Omer shows one of his latest examples of grain matching mastery on this panel that will soon go into the Guest Cabin. Back aboard Möbius and down in the Master Cabin, Omur and Selim start a new job of fabricating the laminated Rosewood liners for the insides of each of the ten hatches we designed and built in house. They use this special laminating material which as you can see is extremely flexible and can be easily shaped and formed however you wish. Solid wood corner blocks are glued in place to provide the backing for the large radius corners of each hatch. Then successive thin layers are glued up, let dry and the next layer applied.
We will pick up on this process next week as the laminations continue and then the solid Rosewood edges and veneer goes on to finish these beauties off.
NEW ARRIVALS THIS WEEK:
The pace of ordering picks up as we get nearer the end of the build so there are more and more new arrivals showing up each week now and here are a few quick examples to leave you with.
Like these four bolts of leather for our interior walls and ceilings!
One bolt of black leather for the Helm Station surfaces and ceiling above to minimize reflections, one bolt of white leather for the removable ceiling panels and two bolts of this gray/green leather for the upper wall panels. Can’t wait to see and be able to show you these as they get installed! And then five cartons like this one from LiteMax in Taiwan.
Can you guess what’s inside?
Yup, our five sunlight readable monitors!
Two 19” ones side by side at the Main Helm station, two 24” side by side up in the SkyBridge Helm and one 43” on the Starboard/Right side of the Main Helm Chair.
I think Captain Christine likes them. As well she should as she spent months researching and tracking these down. Our requirements are eXtreme as usual as we need monitors which are:
Full Sunlight readability (1000 nits+) most new smartphones are about 200-280 nits
Dimmable all the way to black for night watches using real front mounted buttons and knobs
Multi-Touch enabled (PCAP) same as your phone
SXGA resolution 3840 x 2160 or better
Waterproof & Ruggedized
Oh, and affordable too please!
A tall order to say the least and Christine and I would like to give an eXtremely BIG shout out and thanks to Peter Hayden of mvTanglewood fame for all his help in the early stages of this search as a result of all his efforts in searching for monitors for his previous Nordhaven 62 and now the new N68 he is having built. Peter had tracked down several of the companies who are the OEM Original Equipment Manufacturers for these kind of high end monitors for the marine industry. If you are not familiar with Peter’s work on mvTanglewood and his constant flow of expertise on the Trawler Forum, do yourself a favor and go check this out ASAP. Peter is an endless source of great ideas and expertise and writes outstanding explanations of his work and experiences. A MUST read for Christine and I and we hope to share an anchorage with our two boats in the not too distant future.
This led us eventually to LiteMax in New Taipei City in Taiwan who make the monitors for airports, railways, stadiums, ATMs and the like and who were willing to make us the Goldilocks just right monitors for us. It took several months of working with them to get these speced and built and then air freighted to us here in Antalya but they arrived his week and we could not be happier as you can see from my Captain’s face!
They only arrived on Friday and we had a busy Saturday with no time to do anything more than unbox one but we hope to get them setup and tested next week and will bring you more details then. Just one of the literally thousands of decisions we make and problems we solve every week on this grand adventure of designing and building our just right new boat and home.
Thanks for joining us, please put your comments and questions in the “Join the Discussion” box below and we’ll see you here again next week.
Another busy week here at Naval Yachts for all of Team Möbius as we ramp up for the final push to launch as early in the new year as possible. It remains a labour of love for Christine and I but it certainly is all consuming of our time and attention. This week saw progress in everything from CNC machining the new Tiller Arm now that the Rudder is pretty much finished and ready for installing in the hull to finishing the installation of the prop shaft tube into the hull, plumbing for the in-floor heating system, wiring and of course lots of cabinetry work. It will take me awhile to get through it all for you so grab a beverage and a comfy seat and let’s go aboard Möbius and check it all out.
Most of our work with Aluminium to date has been with large plates which are CNC cut to shape and pieced together to form the hull and superstructure. However as you can see in this photo this hunk of aluminium beauty ain’t no plate!
If I tell you that this 152 x 255 x 275mm (6” x 10” x 11”) and 30kg/66lbs block of solid aluminium is just one half of the part, can you guess what this is going to be?
That 150mm/6” long 25.4mm/1” precision ground threaded pin is specially hardened steel to easily withstand the eXtreme forces which can be exerted on it where the Heim Joint ends of the cylinders attach to the Tiller Arm body. I ordered these and 2 spares from McMaster Carr and brought back with me from our recent trip to Florida.
A bit of a no brainer given the title of this section I guess!! A Tiller Arm.
These two quick screen grabs show the design I came up with using Autodesk Fusion 360 which I must say is my all time favorite design and drawing software of all time and in my case that is a LONG time!
You can see how the right side is the second half I mentioned and those four large bolts clamp the Tiller Arm to the 127mm/5” Rudder Post with the 20mm key that goes in the slot on the left side main body.
Turning on some hidden components you can see how the two Kobelt 7080 bi directional hydraulic cylinders with a bore of 76mm/3” ID and stroke of 305mm/12” provide plenty of torque as they push/pull the Tiller Arm which in turn rotates our big rudder up to 45 degrees to each side.
eXcessively massive, time consuming and expensive? Of course, this is an XPM! and the steering system is arguably the most important system on a passage maker so I’m delighted with such eXcess.
Each cylinder is connected to its own dedicated Kobelt/Accu-Steer HPU400 Hydraulic Power Unit. Dennis and I worked extensively with the great engineers at Kobelt to come up with this eXtremely robust steering system. We have designed it such that just one cylinder and one pump significantly exceed the steering requirements to safely steer the boat in even the most severe conditions.
There will be controls at each Helm station to allow us to select either Steering A or Steering B and our SOP Standard Operating Procedures will be to alternate using A and B for a week or so to ensure both systems are fully operable and being used equally. At any time for situations such as close quarter maneuvering we can have both pumps and both cylinders working at the same time which cuts our lock to lock rudder time in half.
In the unlikely event that both pumps and cylinders were to fail we then have a Kobelt 7005 manual hydraulic steering pump with wheel at the Main Helm. And if all of that were to somehow fail we then have an emergency tiller which can manually control the rudder.
Back to real time photos, the CNC machining is all happening in a building 2 blocks over from Naval Yachts here in the Antalya Free Zone at Tasot Waterjet Cutting Technology. They have a small warehouse filled with some of the most advanced metal cutting machines of every description and having the literally next door is one of the great advantages of building here in the Free Zone.
Here is the whole gang responsible for transforming my design into a very real aluminium Tiller Arm. From right to left, Yigit our XPM Project Manager, Hamdi Uysal CNC machinist, Ufuk Bekci Tasot Owner and Tuncay Mutlu Production Engineer
This is the 5 axis CNC machine in the middle of machining the body of the clamp block. Closer view of the Clamp Body with one side finished and ready to be flipped over to machine the other side. Hamdi proudly showing the finished Clamp Body. One half done, now on to the Tiller Arm Body. With one side of the main Tiller Arm body finished, roughing out the second side begins. Easy to see why this is called “subtractive manufacturing”. 3D printing is the opposite “additive manufacturing”. Here is a short little video I’ve put together to show you what this looks like in action.
I was too busy on Friday to get back to see the finished Tiller Arm body so I’ll show you that in next week’s update.
Meanwhile back at Naval Yachts, the Rudder is all finished and patiently waiting to be installed as Nihat and Uğur ae busy getting the 10mm thick walled 200mm ID Rudder Tube tacked in place as they prepare to insert the finished Rudder. Choosing a few relevant layers in the 3D model and using “ghost” mode this quick render will help you see how the various pars such as Rudder, Prop, steering cylinders and Tiller Arm fit together. This is in the aft end of the Workshop with the door out to the Swim Platform in the upper left.
In reality mode here is the Rudder Post Tube now tacked in place and just sticking up above the Rudder Shelf. Same Workshop to Swim Platform door on the upper left. Next week when the Rudder Post Tube is fully welded in place you’ll see the Rudder post sticking up through this tube with the Jefa self aligning needle bearings top and bottom and the Tiller Arm on top. Looking underneath the Rudder Shelf reveals the 25mm/1” thick AL brackets which tie the Rudder Post Tube to the stringers, frames and prop tunnel of the hull and make this all one integral hull assembly. Limber Holes or ”Mouse Holes” in the corners where these tube braces will be welded to the hull plates ensures that any water which finds its way in here can easily flow to the lowest point and be removed by the bilge pump and not trapped in these compartments.
PROP SHAFT & LOG MOUNTING
You may recall from an update a few weeks ago that the machined Aluminium tube, the one with the holes in it here, which the Nogva CPP prop shaft runs inside of, had been fitted into the larger aluminium prop tube that is part of the hull which you can see running up to the top left corner here.
See something new though?
What’s that Orange stuff in that little stubby bit of pipe? And what might this bit of kit be that is on the floor just below the prop shaft tubes? And what are they mixing up here? Some of you will recognize this quite universally used Chockfast Orange which is a special 2 part compound which is pumped in fill voids between two parts and rather permanently fasten them together once it hardens. After being thoroughly mixed with the hardener the syrupy Chockfast Orange is poured into the red tank you see in the photos above, the lid is bolted down and the tank is filled with compressed air.
Then a tube connects the bottom of the tank to the filler tube which is temporarily welded to the hole in the top of the hull’s prop shaft tube and the Chockfast flows into the 12mm/ 1/2’” space between the outside of the Nogva Prop Log tube and the larger inside diameter of the Hull’s larger welded in prop tube. Up inside the Engine Room, the other end of the prop tubes which have been precisely locked into position with this clamping jig and a tube has been inserted into the pipe that has been temporarily installed where the two tubes have been sealed off to stop the Chockfast from leaking out. A few minutes later the Chockfast has filled the entire void between the two tubes and exits out the tube. Several cupful’s are collected to make sure any entrapped air escapes and then the valve on the Chockfast tank is turned off and we leave this to fully cure in the next 48 hours. Once fully hardened the two tubes become essentially a single part and provides plenty of space for water to surround the spinning prop shaft at its center. With the Chockfast fully hardened the prop shaft was fitted again to double check the position of this red flange which will soon be bolted to the output flange of the Nogva CPP gearbox.
Where the prop shaft exits the prop log tube there will be a “dripless” seal that fits over the end of the prop tube and seals against the spinning prop shaft to keep all water where it belongs; in the sea and outside the boat! A close up view of the threaded push/pull Pitch rod which runs inside of the prop shaft. This rod threads into the Nogva gear box and is moved fore and aft by the Pitch Control lever at each Helm. As the rod moves fore/aft the four prop blades rotate in synch and changes the pitch to anything from neutral, forward or reverse and as more pitch is added the speed of the boat increases. All a very simple and mechanical system which gives us the ultimate prop, one that is perfectly pitched for any condition. At the propeller end of the prop tube, water exits out these holes drilled around the circumference of the machined end of the Nogva prop tube.
Next week the Cutlass Bearing which supports this aft end of the prop shaft will be press fit into place and the CPP prop and shaft assembly can be carefully slid in place for checking of the final fit as we prep for installing the Nogva CPP Servo gearbox. ELECTRICK GRILL One of the many items in that big crate you saw arriving from Florida last week was our Kenyan “Frontier” 220V electric grill that is part of our Outdoor Galley on the Aft Deck. We no sooner took the box out of the crate than Nihat and Uğur whisked it away and cut in the opening for the grill in the Starboard/Right Vent Box. Deciding to go all electric for this BBQ was part of our ability too make Möbius be a single fuel, all diesel boat. The other big part of this was going with an internal diesel engine in our Tender and I’ll have more for you on all of that in the coming weeks.
All the top surfaces of these two Vent Boxes on the Aft Deck will be countertops, probably using some of the left over turquoise granite from the Galley countertops. There will be a SS sink in the open space you see here in front of the grill.
Speaking of electrical, I only managed to catch a few shots of Hilmi and Okan’s progress with some of the wiring this week. Okan was busy in the Basement prepping these cable trays to be mounted on the ceiling which will be used to support those huge 120 mm2 / 5/0000 AWG red and black cables.
Cihan was also a busy boy this past week installing plumbing pieces for several different systems.
He has masterfully crafted these two manifolds for some of the Cold and Hot water systems for moving water from one of the six tanks to another as needed to adjust ballast as fuel is removed and others for getting water from the watermaker you saw last week, to each of these tanks. He has done a beautiful job of insulating all of these to increase efficiency of the DHW Domestic Hot Water lines and also keep the Cold water lines from absorbing ambient heat in the Workshop when we are in hotter tropical climates. Moving forward to the Basement, more of Cihan’s fine work this week was getting the dedicated Galley Water tank in place. This is probably more “eXcess” as we can hold as much as 7100L/1875USG of potable fresh water in our six integral tanks in the hull and we have the 190L/hr / 50USG/hr Delfin watermaker. However as you’ve read previously and often, we always design with our “Readiness for the Unexpected” in mind and this additional 200L/55 USG polypropylene Potable Water tank is one example. We will treat this similar to the Day Tank for our diesel fuel by keeping it full at all times and it will be plumbed to an independent faucet at the Galley sink.
Wonder what that shiny item sitting atop the Water tank is? Yet another bit of kit out of that crate from Florida, this is the manifolds for the three in-floor heating zones. To my eyes it is a beautiful work of art in its own right and is almost a shame it is down in the Basement where not too many eyes will see it. The top 3 red towers are flow meters which you adjust with the white knobs on the bottom. After some discussion, Yigit, Cihan and I decided this would be the best location for these manifolds, secure against the WT Bulkhead with the Guest Cabin on the other side. Supply of hot water enters on the top right and goes out to each of the 3 in-floor zones from the bottom of the Red upper manifold and then returns through the three fittings under the White knobs and back to the Domestic Hot Water system on the bottom right. Ball valves on all lines coming in and out and temperature gauges on both supply and return so I can monitor the difference.
Each zone has one of these 3 speed 1/25HP pumps on the supply side to keep the water circulating through the 15mm PEX lines embedded in the floors. In the foreground on the left is a Watts mixing valve plumbed into the floor heating water system to help manage the lower temperature water needed for in-floor heating which wants to run between 30-500C/85-1200 F.
In the background is the Azel I-Link three zone Pump Controller which is controlled by individual temperature sensors embedded in each cabin floor.
I’ll have more to show you as Cihan progresses with the installation.
My Beautiful Bride, aka Captain Christine is at the shipyard most days now and here she is going over the details for the cabinetry and fixtures in this Guest Cabin Head/Bathroom. Standing in the Guest Shower for this shot you can see that Omer has been practicing his cabinetmaking craft very well in this Head. With the Guest Cabin serving as her Office the majority of the time and with this Head being so close to the SuperSalon entrance and the aft Workshop, it will likely get more use than the Head in our Master Cabin so worth making sure it has the Goldilocks touch of being “just right, just for us”. Christine spent a LOT of time searching for this just right sink and finally found one and had it shipped to me in Cannes when I was helping out Naval at the boat show there back in October and I brought it back on the plane with me.
Raised platform in the back is where the VacuFlush toilet will rest at the Goldilocks height. Up in the SuperSalon Omur and Selim continue to make great progress. Here Omur is putting in the perimeter framing for the rigid foam insulation on each stair tread leading down into our Master Cabin. All the floors have 40mm/1.6” thick rigid foam board which the 15mm PEX tubing is embedded into and then some of that light weight poplar 10mm marine plywood covers that and the edges of the plywood attach to these epoxy coated solid wood frames. Opposite the stairs where Omur and Selim are working you can see how this white framing also provides the perfectly level foundation for all the cabinetry to mount to. By week’s end the wall boards were being fitted and will give you, and us, a better sense of how this room will look.
The large opening on the far right is for a 50” high def monitor which will serve double duty as both our primary entertainment screen for displaying movies, photos, web browsing, etc. However it is also on a 3 axis mount which enables us to pull it out and rotate it forward where it is perfectly aligned for viewing charts and boat data from the Main Helm chair when underway.
The large vertical openings on the far left will soon house two Vitrifrigo 130L/35USG fridges with doors opening from the center. The center cabinet is for two of Vitrifrigo’ s band new DRW70 70L/19 USG slide out drawer freezers which can double as fridges with a simple change of their thermostats.
Over in the Cabinetry Shop I happened to catch Omer as he was gluing up one of the Galley drawers and shot this sequence of shots for those of you who have been asking how the wood “biscuits” I’ve been mentioning work to align and strengthen the glued up wood joints.
You can see 2 biscuits with freshly applied glue on the right…. One of the drawer sides which has a matching grove for the biscuit is slid in place. Same thing for the opposite side. Two biscuits and some glue for the final drawer side. Thanks to the ingenious biscuit power tool which cuts all these grooves everything lines up just right. The biscuits are made from highly compressed wood fibres so as they soak up the glue they expand and make the joint even tighter and stronger. Rinse and Repeat the process and this collection of glued up drawer carcases starts to form. Once the glue dries plywood drawer bottoms slide into place and are glued and screwed in position to create very stable drawers which slide in and out on their ball bearing self closing slides with just a touch.
Remember that crate we build and filled with all sorts of parts and equipment that we were sourcing out of the US and arrived last Friday? Uğur helped me open it up and unpack it all this week. Literally hundreds of items inside from Milwaukee cordless tools for me to premium Belgium made pots and pans for Christine and then LOTS of parts for Möbius and they all made it on their flights from Miami to Antalya just fine. Two of Möbius’ items whose arrival we are most excited about are these two bright red beauties from Electrodyne. I have been working closely with the fabulous people at Electrodyne Inc. for well over a year to have them build these eXtremely heavy duty 250A 24V alternators for us which combined will put out almost 14kW. So when I say that we don’t have a generator onboard I guess that’s not entirely true?!
** WARNING: mini Tech Talk Ahead! Skip over if not interested
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!
I’d initially worked with Pete Zinck until he retired early this year 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.
What you are seeing in the photo above are two identical Electrodyne G250-24 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. However I will make the serpentine pulley ratios such that their max speed will be about 3200-3400 RPM for even longer life. Dale stripped these down for safer, and slightly lighter shipping and I have not had time to mount the HD steel wiring boxes which house all the wire connections you see here for the six large external direct AC output cables which then run over to the external rectifiers and regulators which I will mount outside the Engine Room with thermostatically controlled fans to ensure they are always running nice and cool and at maximum efficiency. I’ll cover all that in the coming weeks as I get these alternators installed on Mr. Gee our Gardner 6LXB and wired into the electrical system.
I had a list of key features I wanted for our dual XPM alternators running off our single main engine and I knew that it was going to be a challenge to find a company that would build these so with my long past experiences with their alternators I turned to Electrodyne and sure enough they were able to built in all the features I wanted, In addition to being rock solid, high output and lasting “forever”, perhaps the most significant features that I wanted were that they be brushless and I wanted them to have everything other than the rotating stator to be external. No built in regulators and no 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. This also creates an alternator 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.
I will cover these Electrodyne beauties in much more detail in future posts here once I get them all assembled and installed but suffice it to say that I am VERY excited about getting these Electrodyne alternators installed and tested. Equally as exciting are the WakeSpeed 500 Advanced Regulators that were also in this same crate of equipment we unpacked this week and will be controlling and managing our two mighty Electrodyne alternators.
If this stuff interests you as much as it does me then please stay tuned and be sure to subscribe to the blog so you don’t miss any of the new articles as they go live.
OK, now back to our regular programming.
Mr. Gee Gets Naked!
Captain Christine is now working at the Naval Shipyard with me most days now as we make the final push to finish this build and bet Möbius and ourselves back were we belong; ON THE WATER!!
Amongst her many jobs Christine has literally rolled up her sleeves, donned her HD latex gloves and become Mr. Gee’s personal degreaser! Our Gardner 6LXB serial # is 196071 which means he emerged out of the Gardner and Sons building in Patricroft in Manchester England in February 1975 and was in constant use powering a tugboat in the Thames river everyday thereafter. After 45 years of such use we are giving Mr. Gee a serious bath to start his second life as our main engine in Möbius. To do so we have removed every single part, nut, bolt and cotter pin and have now removed pretty much every bit of grease and guck that has accumulated over his glorious 45 year past.
With all the other duties I’ve unexpectedly taken on here along with the regular demands of building a new boat I’ve not been able to get as much time as I had expected to attend to Mr. Gee’s needs but I am contributing more of late and managed to get this massive chrome molly (chromium molybdenum steel) crankshaft all cleaned up and returned to its original shiny self. This is Michael Harrison, the CEO of Gardner Marine Diesel Engines who continues to keep the Gardner name alive and very well. Michael was also the one who found Mr. Gee for us after a very long search for this completely original unrestored marine version 6LXB.
The Gardner 6LXB, and most Gardner engines for that matter are built with four primary building blocks:
Cast Aluminium Oil Pan
Cast aluminium Crankcase
Cast Iron Cylinder Block with pressed in dry liners
Dual cast iron heads
After one of several strip downs, I had reassembled all these major castings and had the exterior thoroughly sandblasted and then put on several coats of high temp silicone based primer.
Now stripped down naked once again and ready for the bath of his lifetime, Hakan helped me drag the bare cast aluminium crankcase outside. Armed with some super HD degreaser, lots of wire brushes and our newly acquired Bosch pressure washer, it was bath time! I had spent the previous 3 days scrubbing every nook and cranny with the degreaser and wire brushes so this final pressure wash took us back down to virgin raw aluminium throughout. I also wanted to be sure to blast out every oil gallery and hole to remove not only the old grease and grime but also any new particles that had climbed aboard during the sandblasting. And here is the result, a VERY clean Mr. Gee! This is the front end of the crankcase which will soon be filed with lots of sprockets and an eXtremely large double roller timing chain that drives everything from the camshaft to the PTO for one of those Electrodyne alternators to the water pump and fuel pump. Whew!! It is now late on Sunday night and I’m exhausted and so are you probably if you’ve made it this far!
Thanks so much for joining us, makes this adventure all the more exciting and rewarding to know you’re out there and along for the ride.
Do please add your comments, questions and suggestions in the “Join the Discussion” box below. Even though I am WOEFULLY behind in responding to those of you who have done so in the past 3 weeks. Rest assured I DO read them all and think about all you say and I will respond to each one in the next few days so thanks for your patience.