Transfer Time:  Wood, Water, Fuel & Air

Transfer Time: Wood, Water, Fuel & Air

We are all back after a wonderful week off for the big Eid-ul-Fitr or Ramazan Bayrami n Turkish which is the “Festival of the Breaking of the Fast” that occurs as soon as the new moon is sighted at the end of the month of fasting.  Well rested, well fed and filled with gratefulness and appreciation for all we have, progress ramped up quickly on the good ship Möbius on lots of different levels and materials.  The title is in reference to the theme of transfer which prevailed this week including transferring the completed Master Bed cabinetry to the finishing shop, transferring to prepping the Master Cabin to have all its cabinetry mounted, and then lots of work with other transfers such as Dorade Vents for transferring fresh air into the interior spaces and transferring water of all forms (Black, Gray, Potable, Sea) to and from their respective tanks.  Whew!  That’s a LOT of transferring and too many words so let’s jump right into the show and tell for this week of June 10-14, 2019.

IMG_20190613_154102Starting with the transfer of diesel fuel the Day Tank was back in the spotlight as it was completed and prepped for installation onboard.
IMG_20190612_142251

Nihat on the right here and Uğur provide a good reference to the size of the Day Tank which holds a total of 667 L / 178 USG which is enough for about a day and a half at 10 knots.  We “polish” all the fuel going into the Day Tank using our Alfa Laval centrifuge which I’ll detail in a future post when we get to installing it.  This ensures that all the fuel going into the Day Tank is super clean and that we are assured to have enough fuel for at least a day and a half on passage.

IMG_20190612_142315Following the “belt & suspender” type of redundancy we insist upon for all critical systems, just to be sure the fuel has no dirt or water in it, we have the round drain pipe you see here as the lowest point in the tank to trap and hold any water or debris that may have somehow made its way into the Day Tank.  There will be a 3/4” SS ball valve on the bottom so I can easily pull and test a sample of fuel from here.


Peeking further inside you can see some of the baffle plates which prevent the fuel from “sloshing” from one side to the other as the boat moves.

The fuel goes through another series of multi stage fuel filters as the final steps in guaranteeing that nothing but clean fuel is being fed to Mr. Gee, our single main Gardner 6LXB engine upon which we are so dependent for propulsion.


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There is this additional access port in the top just in case I ever need to access the inside of the fully baffled tank when it has lots of fuel in it.  Uğur is tapping the holes in the access port frames for the threaded studs that will hold the gasketed lid tightly in place.
IMG_20190612_142215With all the access ports and baffles all welded up the tank is closed up by welding in this last side.  You may recall seeing this type of slot welding when the hull was being built as this is how you are able to weld a plate where you have no access to the inside.
IMG_20190614_102029With the Day Tank fully prepped, Sezgin our Master Welder then gets the call to finish welding the slots and perimeter of this last side and then …….
IMG_20190613_102416……. lay down the finished continuous welds and fully seal up the drain sump and both access ports.
IMG_20190613_102430Looking down through the top access port down to the one on the bottom, you can see more of the baffles which minimize the weight transfer as the fuel moves about when there is lots of boat motion.

Next week Nihat and Uğur will wrestle this completed Day Tank into the Starboard/Left side wing of the Workshop and fasten it into its full time home up against the WT Bulkhead. 
IMG_20190610_182351Making sure we keep Mr. Gee VERY happy and running well we we also need to feed him cold clean air and that is what Uğur and Nihat are working on here in the Engine Room.  That long rectangular aluminium duct will carry fresh air from the Port/Left Vent Box up above on the Aft Deck down to the floor of the Engine Room.
Aft Deck Vent BoxesOutside looking at the Aft Deck this quick rendering shows how the two Vent Boxes provide additional height and a protected place for the mist eliminating vents that will be on the inside of each Vent Box.

These Vent Boxes will also serve as our outdoor Galley with a BBQ in that aft cut out of the far Vent Box and a sink in the nearest one.
Vent Box ductingThis isolated render of the Vent Boxes in Red and their respective below deck ducting in Purple will hopefully help you see how they direct air into and out of the ER as well as air into the Workshop and the Guest Cabin.

The tall purple duct on the left takes the intake air down to floor level in the ER while the smaller purple ducting on the far side pulls the hotter air out of the ER up and out through the upper demister grill outlined in Green.
IMG_20190611_085546Back to the real world, here is that tall intake duct you saw above as it extends up through the aft deck plates.  The vent box sitting in the top right corner will eventually be fitted overtop of this duct and the air will enter through a demister grill on the inside surface of the Vent Box.
IMG_20190612_103747Back down in the Engine Room looking up at the ceiling on the Starboard/Right upper forward corner we see where the hot ER air exits.  There will be 24V fans to assist with pulling the heated ER air out and creating a slight vacuum in the ER to make sure none of the fumes and heat are pushed out into the Workshop.

The large radius duct all the way forward penetrates the ER enclosure wall and feeds fresh air into the Stbd/Right wing of the Workshop.
Dorade Boxes ForedeckMr. Gee isn’t the only one who needs to be fed lots of clean fresh air, we do too!

When we are on passage and most often can’t have the hatches open we bring fresh air into our Master Cabin with these four Dorade Vents seen here on the Foredeck.


IMG_20190613_103618Dorade Vents are a very tried and true way of bringing fresh air into a ship while also keeping rain and sea water out.  Very simple principle, a tall vent pipe such as the three you see here (forth hiding behind orange welder) set up about 150mm / 6” above the deck and carry fresh air straight down into the cabin.
IMG_20190611_085524I’m determined to have a zero leak boat so I have a zero tolerance policy for any penetrations through the hull.  For example yes of course these vent pipes are welded to the deck top and bottom! 
IMG_20190613_103755These vent pipes are then fully covered by the Dorade Box which Uğur has mocked up a prototype of and is lowering in place here.
IMG_20190613_103746These aluminium Dorade Boxes will be welded to the deck with generous scuppers/slots all along the bottom edge to allow any water that gets in to quickly drain out of the box onto the deck and back overboard.
Image result for dorade boxThen a silicone cowl assembly like this will be mounted on the top aft surface of the Dorade Box to capture the fresh breezes coming over the bow and direct them down into the Dorade Box.  The cowl can be rotated 360 degrees and the mushroom cap you can see in the bottom cutaway section helps deflect rain/sea water out the vent slots around the base and any that makes it down into the Dorade Box below drains out through the scupper slots noted above.
Image result for dorade boxA side section looks like this when you put it all together.  No matter what the weather or sea conditions we get fresh air in and keep water out, just the way we like it!  If we want to really seal these off we just reach up into the vent pipe and turn that little black knob you see in the section above which lowers the mushroom cap and seals it off.  We will also have a bug screen atop the vent pipe to keep those guys out as well.


IMG_20190613_103108When weather and conditions permit though we prefer to have our beautiful big hatches open to let in even more fresh air and lots of light.  So our in house designed and built hatches got some finishing touches as well this week, having their Hinge Boxes all welded up inside where they join the inner deck plate surfaces and tie into the support stringers. 
IMG_20190613_103125Still looking up at this hatch frame we see one more example of how we make sure lots of fresh air gets in while keeping water out with this drain elbow that carries any water that collects in the gutter around the hatch frame out through a hose into an exiting sea chest.
IMG_20190614_102240Continuing with our transfer theme and moving to the Guest Cabin area you can see the black fuel hoses at the bottom of the Starboard/Right side of the hull.  Two of these hoses will carry the diesel from the integral tanks under all the floors to and from the Day Tank which will be mounted on the other side of the WT bulkhead on the far right of this photo.

As you can see the hull walls are starting to fill up with more hoses and electrical cables. 
IMG_20190614_102255Looking a bit like tentacles of some stowaway octopus these hoses are being fed through their respective through holes in the frames and through the welded in penetration collars where they pass through a WT Bulkhead.  Trays similar to the white wire trays you see above will be mounted horizontally to aluminium flat bars that are hiding under the vertical strips of black EPDM insulation you can see on the right but for now they are being routed throughout the length of the sides of the hull.
IMG_20190614_102419Each different type of fluid needs to transferred using a different type of hose specifically made and approved for each purpose.  In this case these clear 19mm / 3/4” ID hoses are for transferring any bilge water which might collect in the gutters running down each side of the hull where the tank top margin plates aka floor, intersect with the side hull plates.  With all integral tanks for fuel and water filling up all the area below the waterline the only place where we have a traditional bilge is below the main engine.
IMG_20190614_102854Moving forward into the Basement area you can see these clear bilge water hoses coming through up near the top of the WT Bulkhead, black fuel hoses on the bottom and the white/blue hose which is for transferring Gray Water from sinks and showers out of the integral tanks below the floors to either an Exit Sea Chest or a shoreside pump-out station.


The black & red pump is one of 18 Johnson SPX Power 16 diaphragm low level bilge pumps which we use to suck up any water that collects in those margin plate gutters along each side.  One of the many benefits of using diaphragm rather than the more common centrifugal bilge pumps is that diaphragm pumps can be located high and dry and they are also able to pull up all but the very last little bit of water.  This is a HUGE improvement and keeps the boat dry and odor free.


IMG_20190614_102528Another example of the specialised pipe and hoses showing up onboard is this white PPR tubing which we’ll be using for the main hot water loop that supplies hot water to all our sinks and showers.  This 25mm / 1” ID pipe will create what will essentially be a large hot water manifold that runs the length of the boat with a very small thermostatically controlled circulation pump which keeps the water at a set temperature.
IMG_20190614_103205Each length of PPR is fully wrapped with this EPDM foam insulation to keep that heat in and increase the efficiency of our overall water heating.  This is the same type of EPDM foam which we have at least 50mm / 2” of covering every interior aluminium surface to create our live in Thermos bottle. 

Our water is heated by a variety of sources, primarily from the Kabola diesel boiler and then supplemented by a heat exchanger off the Gardner main engine when it is running or from electrical coils when the solar panels have already fully charged the house bank batteries.
IMG_20190614_103123There will be T’s coming off this main hot water loop with short runs of equally well insulated 15mm PEX tubing carrying hot water to each individual sink and shower tap.

What all this does is provide near instant hot water to each sink and shower and eliminates the all too common waste of our highly valued fresh water from our watermaker when you turn on the hot water tap and wait and wait for it to get hot.
IMG_20190611_085150Hey!  What happened to our beautiful King bed??
IMG_20190531_144830When we last saw it just before we all left for the holidays it looked like this!

Oh!  More transferring you say?  Right, the bed all comes apart so it can be moved aboard through the available openings, got it!
IMG_20190612_162223Omur and Selim first finished off the base for the mattress with the two removable hatches to provide access to the two large storage areas not filled up with drawers.
IMG_20190612_162234We are loving the contrast between the light coloured Beech being used for these kinds of areas with the dark Rosewood everywhere else.
IMG_20190613_101900One last detail was to route in these slots to provide more ventilation below the mattress and now the whole bed is ready for the next exciting stage; applying the final finish!
IMG_20190612_162343But before we leave the Cabinetmaking shop one more detail I thought you’d enjoy seeing.  This is an example of how to reduce weight onboard.  These are not for Möbius but for another boat Naval is now finishing up and these are the interior doors. 
IMG_20190612_162348Frames are all made from laminations which ensure they are very rigid  and stay flat with no warping.  Extra thickness is provided where hinges and latch hardware will be mounted.  All the cavities have lengths of extremely rigid foam bars glued in place which weigh next to nothing.   Then the door skins are glued on both sides, the whole assembly trimmed to final size and off to the veneer press to have the final layer glued down.  Strong, stable, lightweight and beautiful, who could ask for more?
IMG_20190613_155739Hang on!  Who let Omur and Selim out of the Cabinet shop and into the Master Cabin on Möbius?? 
IMG_20190614_103008Oh right!  This is where wood meets metal.  They are meticulously putting in the wood foundations that all their cabinets will set on and be attached to.  Omur is measuring out the end of the bed unit you’ve seen previously and can see the outline of here. 
IMG_20190614_103040Behind him is this framing around the four access ports into the integral water tanks below all the floors.  These solid wood frames are all sealed with epoxy paint, carefully leveled with the wedges you see here and then glued down to the aluminium tank tops/floor plates with Sikaflex.
IMG_20190614_174702Once all these foundations are laid down all the cavities will be filled with 40mm / 1.6” rigid foamboard and then 10mm marine plywood will be laid down to create the substrate for the final vinyl flooring. 

Before the plywood goes down the foam will have all the grooves routed in place to create the continuous circuits for the 15mm PEX hot water tubing to be pressed into for the hydronic floor heating that will be in all the living spaces on Möbius.


Those with sharp eyes and good memory, I wish!, will note that the walls in the Master Cabin are also filling up.  I’ll cover them in more detail in future posts but the large 50mm / 2” clear tubes are the vents and fills for the water tanks, the smaller 19mm / 3/4” tubing is what you saw earlier for the low level bilge water and the long arced pipe with EPDM black foam insulation running horizontally half way up the wall is the one you saw earlier for the continuously hot water loop/manifold.

But wait!  There’s more!

IMG_20190613_102211Why is Aziz, Director of all Naval’s Interior work, smiling almost as much as me? 
IMG_20190613_102207Because we are both up in the Finishing Workshops looking at THIS!  The first coat of lacquer being applied to all the bed unit pieces. 
IMG_20190614_101541Words can’t begin to capture and articulate my excitement and joy in seeing this whole new stage of the build taking place so I’ll let the pictures do all the talking.
IMG_20190614_101615Here is a bit of a before and after shot with the drawer faces in the foreground being the bare Rosewood and the ones in the background having their first coat on.


IMG_20190614_101715We have decided to use this top quality acrylic lacquer from Sayerlack which is a Sherwin Williams line of finishes for commercial cabinetmaking shops.  Lots of reasons for the choice over the more traditional varnishes but one of the big differences is the ability to have a hand rubbed finish.  I have worked with acrylic lacquers for decades in my prior woodworking and antique car restoration days and it is hard to beat the beauty of a hand rubbed finish.  A HUGE amount of added labour but as I think you will soon agree when you see the final result it is SO well worth it.


IMG_20190614_101338This is just the first coat and BEFORE these other pieces of the Master bed unit have been sanded smooth prior to the next coat so just wait till you see them when they are fully finished and rubbed out.

Whew!  Obviously things quickly got up to speed as we all returned fat and happy after the big Bayrami  holiday week.

With such a wonderfully diverse spectrum of interests all of you reading this have it is a challenge to gauge the just right amount of detail to provide in these posts.  I tried to cover all this progress as quickly as I can but it is still quite long so if you’ve made it this far thanks for persevering.  Hope you enjoy it and please do let me know in the “Join the Discussion” box below what you thought and add any questions or ideas you have to add to the value for all of us here.

Thanks!

-Wayne

Drawer-ing to a Close

Drawer-ing to a Close

Progress for this last week of May 2019 was all about finishing the cabinetry for the King bed unit in our Master Cabin.  The focus was on completing the construction of all twelve drawers that make up the large high base, hence this week’s title, as well as finishing the dropped overhead ceiling of the headboard.  My brother Bruce and wife Lyla flew out early Friday morning and my cousin Donna and husband Jamie flew in a few hours later from Doha in Qatar so there are still no vacant rooms at the Hodgins Bed & Breakfast and we are enjoying getting all this extended time with friends and family as we share this fascinating part of the world and all the wonderful people, culture and food.

Right now though, let’s go to bed OK?

For those who might be new to these weekly progress updates on the building of our new home/boat motor vessel mv Möbius, Welcome, and here are some of the early renderings of what the whole bed unit and Master Cabin will look like when completed.  We’ve made a few changes as you’ll see in the real life construction pictures here but the overall layout remains the same.

02This is what the King bed and drawer unit will look like when you are standing near the front of the Master Cabin looking aft.  The two wardrobe doors on your left will end up being wood and upholstery rather than glass and all six slots at the end of the bed will be drawers but most else stays the same. 


You’ll note some steps to get up to the raised floor on the right/Port side of the bed to make it easy for Christine and Barney to get up and down from there and making the bed easier. 

01Stepping a bit further back and looking down the centerline of the boat you can see part of the Washer & Dryer cupboard doors on the left and the etched glass cornered walls of the shower on the right.
04Moving over to those steps and looking across the end of the bed towards the Starboard hull shows the large bureau of drawers with the 3D Möbius strip sculpture floating in the space above and the other full height wardrobe by the entrance door in the far right corner.
03Standing just inside that entrance door on the other side of the bed looking forward gives you a good look at that glass cornered shower with the adjoining toilet forward and the Vanity sink outside at the very front.
IMG_20190531_144927Jumping back into reality and forward to the end of the week here is what the real Rosewood bed unit looked like.  I will rewind the clock to Monday morning now (May 27) and we can watch the progress of getting to this point.
IMG_20190527_112654I am holding one side of the very slick drawer slide hardware we will be using for all the drawers throughout the boat.  These are the latest version soft close bottom mount drawer slides from Blum hardware, which makes the highest quality drawer slides I know of.  Once the drawers are in place it all becomes invisible and they glide open and close like silk.
IMG_20190527_112706The drawers sit on top of the left rail you can see with the little finger clip you can barely make out at the far end (click to enlarge any photo) and that light grey cylinder on the right is part of the incredibly smart open/close mechanism.  When you go to open the drawers there is a spring loaded resistance for the first 50mm/2’ or so before the magnetic latch releases and the drawer slides smoothly open as far as you like in a two stage extension.  Then a light push and they slide forward till the magnet catches it and slowly closes the rest of the way and holds it tightly closed.  Perfect setup to keep all the doors closed as the boat tilts and rolls at anchor.  We then have additional latches to mechanically lock the drawers closed whenever we are on passage and the boat’s movement an become more pronounced.  They’re expensive but they are SO worth it for the smile they put on our face every time we open or close them.
IMG_20190528_103959Moving on to the construction of the drawers themselves, this is a stack of some of the drawer carcass sides fresh out of the veneer press after their solid Rosewood edging had been glued in place.
IMG_20190528_103540Selim uses this random orbital sander to smooth and flatten the drawer sides while they are easy to get at before being glued together into a complete drawer carcass or box.
IMG_20190528_170212Upper solid edges of the four drawer sides are rounded over and then …..
IMG_20190529_101949…. each matched set of drawer sides are set in their respective drawer slots under the bed ready to be fitted and glued up.
IMG_20190528_170027With dados/grooves and biscuits cut for the corner joints and for the drawer bottoms to slide into, Omur checks that the diagonals are equal as the best way to ensure the drawers are being glued up exactly square while Selim stands ready to clean up any glue squeeze out before it dries.
IMG_20190528_170111Looking at the rounded top edges of the drawer shows how the back side is set a bit lower to allow air to easily move in and out as the drawer is opened and closed.
IMG_20190528_103617With the drawer sides all glued up and drying, attention turns to the individual drawer fronts, seen here with their solid Rosewood edging mitre glued in place.
IMG_20190530_103810Before taking them over to the veneer press Omur carefully fits each drawer front so they all have the same 3mm space around them using 3mm thick shims, two of which you can see sitting atop the bottom drawer here.

Glued up drawer boxes wait patiently on the left to receive their drawer bottoms and then have the front faces attached.
IMG_20190530_103826Using 3mm spacers he trims each drawer front to final size.  Our eyes are very good at noticing the slightest variation in such thin slots such as between each drawer front so this requires great care and attention to get them perfectly parallel and evenly spaced.
IMG_20190531_144907Once each drawer front has been trimmed to final size they head off to the veneer press to have both front and back covered in matching Rosewood and once dry every corner edge is rounded over with an 8mm radius and they are ready for their final fitting.
IMG_20190531_144911The drawer faces are taped in place so they don’t fall out as this is all part of the dry fitting before all these parts are finish sanded and ready to head off to the finishing shop where they will be varnished and buffed to a beautiful matte finish and then assembled onboard.
IMG_20190531_144901If you spotted this black strip in the photo above and wondered what it was for, this is a sample of the thin coloured strip that will form the “Horizon Line” I’ve described in previous posts which will flow horizontally throughout all the cabins in the boat.  This is just a sample for fitting purposes and the final strips will be a random swirling pattern of aqua marine blues and greens to simulate the water and waves which make up the horizon line that usually surrounds us around all 360 degrees of view when we are anchored in the remote locations we most often favor.
IMG_20190527_112738Lest the drawers get all the attention this week, Omur and Selim also spent time finishing the dropped ceiling that sits directly overtop the head of the bed.  We have dropped it down a bit further than in the renderings above but same basic layout. 
IMG_20190528_170243With the 15mm / 5/8” plywood bottom of the dropped ceiling box glued in place the Rosewood edges are all radiused and prepped……
IMG_20190529_125822 …… the ends are have their locator dowel pins installed and biscuit slots cut ready to be fitted into the headboard and vertical side posts…….
IMG_20190529_183033….. and temporary braces are clamped in place to do the final fitting of the dropped ceiling to headboard joints.
IMG_20190531_144822All this attention to detail will seem over the top to some perhaps but not to us when our eyes behold results like this! 

As your eyes naturally follow the grain patterns in each piece note how they have all been carefully chosen and aligned both vertically and horizontally to be a continuous matching flow of the original grain of the individual tree these were cut from.
IMG_20190530_183022We had a new four legged visitor at Naval Yachts this past week when Hakan our CAD Cabinetry detailer brought his super cute puppy “Sheila” to work with him.  This photo will also allow me to introduce one of the newest members to join Naval and Team Möbius.
Please meet Yesim who is our lead Interior Designer and master of 3DMax software which she uses to turn Christine and my visions into fully rendered masterpieces which Hakan can then use to create all the detailed joinery which in turn goes over to Omur and all the others in the Cabinetry shop for them to build things like the bed unit we’ve been featuring this week.
IMG_20190531_144952Speaking of Omur and Selim, no rest for them as they quickly moved from working on the bed to starting to create the panels for all the other cabinetry in the Master Cabin which you see in the renderings at the beginning of this post.

Hot off the veneer press they peel the veneering tape that holds each adjoining edge of veneer in place while it is being glued to the plywood panel.
IMG_20190531_144917Here are the first sets of veneered panels stacked up against the bed unit ready to be trimmed and cut to shape for things like the wardrobes and other cabinetry in the Master Cabin.

Those candle flame like parts of these panels are the matching portions of the natural grain at the transition between heartwood and sapwood of the Rosewood tree.


You will be seeing much more of this as we watch all this other cabinetry take shape.


IMG_20190527_162250Not likely too exciting to most of you but sure is to us as more and more materials and equipment start to arrive for the many systems that are about to be installed in Möbius. 

This pile is a small portion of the hoses that will be used to plumb the fresh and potable water systems.  The coils of blue and red hose are PEX 15mm tubing that will be used for all the hot and cold water runs to sinks, showers, toilets and bidets and also used for all the hydronic heated floor circuits that run through all the floors in each of the three cabins to keep us toasty warm and comfy in all the high latitude locations we want to explore.


IMG_20190527_162430Here is another pile of recent arrivals, this being some of the many diaphragm bilge pumps, domestic water pumps, ball valves, strainers, etc.
IMG_20190528_103753I will close out this week’s progress update with this shot of the Port side of the Master Cabin bed unit which really shows off the full spectrum of grain and colours in the beautiful Rosewood you will soon see throughout the interior of Möbius.  Go ahead, click to enlarge, you know you want to!

Eye of the beholder always applies of course and this makes my and Christine’s eyes sparkle with excited anticipation of being surrounded by this natural beauty every day we will be living aboard our newest floating home and magic carpet ride around the world.


This coming first week of June is a big national holiday following the end of this year’s Ramadan.  The month of daily fasting ends on Monday and Eid al-Fitr 2019 officially begins on Tuesday, June 4th so all of us on Team Möbius are all going to take advantage of this opportunity to get a few days of much needed R&R this week.  I may put together a post here if I have time as there are several topics I’m meaning to discuss and share and then I’ll get back to the next weekly progress update in about two weeks.

We hope you too are enjoying the start of summer here in the Northern hemisphere and that our southern hemisphere friends and family are staying warm and enjoying the change into winter down there as well.

Whatever part of this awemazing planet you find yourself, thanks so much for taking the time to join us on this latest adventure and be sure to add your questions, suggestions and ideas in the “Join the Discussion” box below.


When your Captain says; “Come check out the new bed with me ……………”

When your Captain says; “Come check out the new bed with me ……………”

I don’t know about you but when MY Captain, aka wife, aka Christine, says “Come check out the new bed with me” I say “Aye aye Captain”!!

IMG_20190525_141457Lucky me, my Captain/Wife said that to me on Saturday when we brought my brother Bruce and wife Lyla by Naval Yachts so they could check out our new boat.  It had been over a week since Captain Christine had been to the cabinetry shop so she had not seen our Master Cabin bed assembled and it was a real treat for both of us to see the previous models and renderings being transformed into real Rosewood furniture at the expert hands of our Master Cabinetmaker Omur and his assistant Selim.
We have had a non-stop stream of friends and family coming to visit and staying with us for the past month and that continues for several more weeks so we are having an unusually full social life these days which has been wonderful.  However it doesn’t leave much time for putting together blog posts and answering questions on all the various mediums and forums so thanks very much for your patience with these delayed posts and responses.  Right now we have Bruce & Lyla with us from Vancouver through the rest of this week and then the same day they fly out my cousin Donna and husband Jamie fly in from Doha in Qatar to spend the week with us.

I will try to let the photos do most of the talking so I can get this already very tardy update with all of last week’s progress uploaded for you.  As always and especially for this rushed update please don’t hesitate to post questions in the “Join the Discussion” box below each blog post.

In keeping with the title I will start over in the Naval Yacht’s large Cabinetry shop where they have been building the King sized bed unit and walk you through all the progress Omur and Selim made on that last week.


02To help visualise this whole bed unit, here are two of the early renderings of our Master Cabin.  You are looking aft while standing up by the vanity sink which is on the WT bulkhead with the Forepeak on the other side.  The glass walled shower and bathroom are on your right and two of forward glass door wardrobes on your left. 
01As you can see the bed is raised about 1m/3ft to provide LOTS of storage below.  We have changed since this early rendering so there will now be 12 large drawers on two sides and then  2 large storage areas accessible below the bed.
IMG_20190520_115832Returning to reality in the Cabinetry shop, here is what the bed unit looked like at the start of last week.  As you can see even the insides of the cabinet where the drawers will go have all be veneered with solid edges in Rosewood, a point Omur was quite insistent upon and yet another example of the level of quality and detail in all the cabinetry work.
IMG_20190520_115842The lighter Beech area will have snap in place upholstered headboard panels and you can see how the toe kick area is recessed all around the base of the bed unit.
IMG_20190520_115944This toe kick detail will be used throughout the interior with these same large radius solid Rosewood corners with the “quilted look” where they join the horizontal grained side boards.  You can also see the groove where LED strip lights will be fitted to provide dimmable indirect lighting at night.
IMG_20190520_115939The whole bed and drawer unit is too large to be moved aboard in one piece so the plywood platform has the profile of the finished unit accurately laid out to assist with assembling all the individual components and temporary cleats like the one you see here are screwed to that platform to hold them in place.
IMG_20190520_120026Standing up near the headboard on what will be Christine’s Port side of the bed, you can see how the vertical plywood pieces have been slot fitted together so they can be disassembled to move aboard and then reassembled easily there.
IMG_20190520_120327Omur on the left and Selim are dry fitting the angled corner using biscuits and then these will be glued up when assembled onboard Möbius.

IMG_20190520_153730Biscuits are also used to join the solid Rosewood edged drawer frames and these too will be dry fitted here in the Cabinetry shop and then glued together onboard.
IMG_20190520_153758Some of you were curious about the tool used to cut the arced slot for these biscuits so I pulled the spring loaded fence back so you can see the carbide tipped cutters on the circular blade inside.  I’ve used this same system for many years when I was building cabinets over 30 years ago so this is a very well proven, fast and accurate way of joining these kinds of cabinets.
IMG_20190520_154319The outer corners of the base drawer unit are all solid Rosewood with these large 50mm / 2” radius cut on them.  Any areas such as these which are likely to get the most wear and tear over the years are made of solid wood so that they can be easily sanded and refinished to remove any damages they incur over the years.
IMG_20190520_182210Where these vertical corners join with the solid wood edging of the mattress frame they need to have these inside corners cut out like this.
IMG_20190520_182410And then attached to the sides of the drawer frames.
IMG_20190521_103516Clamps and tape are used to hold everything in place as the temporary assembly continues.
IMG_20190521_111710As explained in previous posts I am very insistent that there are NO sharp corners aboard so all the solid  Rosewood edged corners are radiused such as this vertical corner piece.
IMG_20190521_160819This base level shot along the toe kick shows how this all starts to come together.
IMG_20190523_104152Up on top of these corners this solid piece has been shaped to fit into those cut outs we saw earlier.
IMG_20190523_103917Like this.  Biscuit slot all ready to receive the solid Rosewood mattress frame piece and cellophane tape to prevent the glue from sticking to areas that still need to come apart.
IMG_20190524_145431Here is what the whole dry fitted corner looks like.  The light coloured Beech strip is where the blue/green “horizon line” I’ve described previously will be glued in place. 
These Horizon Lines are part of the overall interior design theme we have come up with and consist of thin 2mm thick strips with wave like swirls of aquamarine epoxy “printed” on their outer surface to simulate the continuous line of the horizon we most often have surrounding us in the remote anchorages we favor.  You will see much more of this in future updates as the interior cabinetry progresses.


IMG_20190525_141430Here is the overall shot of how this all looked at the end of last week May 24th, 2019.

The U shaped Rosewood frame you see below the headboard is the dropped ceiling above the head of the bed which you can see more clearly in the renderings above.  It will be attached to the ceiling of the Master Cabin directly above where it is sitting in this photo. 
IMG_20190525_141443Finishing off this update on the bed cabinetry, here is my beautiful bride model to give you a sense of scale of our overall bed and drawers cabinetry.
IMG_20190520_181255Heading over to the shipyard floor, we find Uğur up on the foredeck doing his final checking of the first hatch lid to have the hinge arms all welded in place. 
IMG_20190520_181244This is the most challenging part of building these hatches as the Hatch Lid frames must sit with their inner surface at just the right distance from the surface of the deck mounted Hatch frames so that the seal is compressed fully and equally against the Hatch frame welded into the decks. 
IMG_20190520_181301Then the upper surface of the Hatch Lids have to be 15mm below the deck surface as this is the thickness of the tempered safety glass which needs to end up being flush with the deck surface. 
IMG_20190523_103454All of this is determined by how the Hinge Arms attach to the Lid frames when the SS hinge pin is installed.  Once they had the technique mastered with the first hatch they could move on to repeating the process for all the other nine hatches.
IMG_20190523_103626With its Hinge Arms tacked in just the right spot the SS Hinge pins are pulled and this Lid has been removed and set in place to await Sezgin’s arrival with his TIG welder to fully weld the Hinge Arms to the Lid.
BUT, as if this wasn’t already challenging enough, the CNC milling machine broke down just before we could use it to cut the profile of these Hinge Arms into a single length of a solid aluminium bar stock.  This would have made it quick and easy to chop saw each individual 50mm wide Hinge Arm from this one length. 

With the CNC mill is down for an undetermined amount of time, what to do now?


IMG_20190521_102813Go Old School baby and cut them by hand! 
IMG_20190521_102759Uğur and Nihat cut 50mm wide blocks of aluminium from a length of 100mm / 4” square stock

IMG_20190521_102807Cut out a thin template from a print of the CAD files and used this to trace the shape of the Hinge Arm onto each block
IMG_20190521_155506The 8mm holes for the SS Hinge Pins were drilled first and used to precisely locate the profile of the Hinge Arms.
IMG_20190522_174239Then Uğur, resplendent in his white Tyvek bunny suit to reduce the aluminium chips from covering him and using a large clamp to keep his fingers well away from the sharp new bandsaw blade,
IMG_20190522_153619was able to cut each of the 20 Hinge Arms to shape.
IMG_20190522_103836He and Nihat soon had a mini production line running and were able to get each of the 20 Hinge Arms all cut, shaped and sanded ready to be welded to each Hatch Lid as you saw above.
IMG_20190522_103412Elsewhere inside we find Cihan, pronounced “Yee Han”, our Master Plumber and pipe fitter up in the Master Cabin putting in the aluminium flat bars to mount the cable and wire trays which will carry all the hoses and pipes.  Each mounting bar is welded in place and then covered with 5mm hard rubber to help insulate them both thermally and electrically before the trays are pop riveted onto them.
IMG_20190516_150902Back in the Workshop you can see how these perforated cable/hose trays look once installed.  These ones are having the AC wiring fitted now as we keep AC, DC and data cables separated so they don’t interfere with each other.
I squeezed in enough time to put together two quick videos for all of you who have been asking for more of those.  First one below is the typical sped up overview of the progress made during the week of May 20-24, 2019 and the 2nd one a short guided tour of the large Forepeak storage area up front and a narrated show and tell of the first hatch to be installed in the front deck.


And to quote Porky the Pig “Th-th-th That’s All Folks!”

Hope you enjoyed and thanks for your patience in waiting the few extra days before I could get this all put together and posted.

Always enjoy getting any and all comments, questions and suggestions from you so you are encouraged to put those in the “Join the Discussion” box at the bottom of each blog post.  If you are enjoying these and want to be notified when new content goes live just hit the “Subscribe” box in the top right corner here.

If you enjoy the YouTube videos please hit the Thumbs Up button and the Subscribe buttons that are below each video.

It is another busy week coming up so it may take me a few extra days to get this week’s update posted so I’ll ask for your patience in advance.

-Wayne

Immersed in Beauty

Immersed in Beauty

For most of my life I have strived to “put myself in the way of Beauty” and as the work on Möbius starts to branch into multiple materials from the aluminium of the hull to the copper of the electrical wiring to the rosewood of the interior cabinetry I find myself in the envious position of being immersed in beauty thanks to all the skilled people working all these materials into what I often refer to as “collaborative works of art and engineering”.  Beauty is a feeling that comes through all of our senses, not just sight and if you come along with me for this week’s progress update tour and I think you’ll agree.


IMG_20190514_172754I will start our tour with the latest aluminium work; finishing the Lids for our in-house designed and built hatches. 

IMG_20190513_181905Last week saw the CNC cut 10mm / 3/8” thick plates being welded to their 8mm thick flat bar frames so this week Uğur and Nihat ground those welded surfaces flat and flush ….
IMG_20190515_163452…. and then polished the outer edges to a beautiful lustre,
IMG_20190515_163440and the stack of polished hatch lids grew higher.
IMG_20190516_150803These polished edges were then protected with blue masking tape and Mehmet cleaned up the inside corners which will be filled and sealed later with a cove of epoxy.
IMG_20190516_150705Then the corners of he bottom edges were machined with a 4mm radius to round over this edge and make it feel as beautiful as it looks.  Last step will be the tricky one of welding the Hinge Arms to these Lids and we’ll show you that next week.
IMG_20190514_105628Several of you asked to see the jig I mentioned last week that Uğur and Nihat fabricated and used to tack the Hinge Boxes to the deck and outer Hatch Frame such that the holes for the SS Hinge pins were precisely aligned with each other and this is it.
IMG_20190514_105611The two tabs on the jig slight snugly into each hinge box and the SS hinge pins are slid in place.

IMG_20190510_162632Using this jig, Uğur presses each Hinge Box up tight against the underside of the deck and the outside of the Hatch Frame and slides the SS hinge pin through the jib and boxes.  This holds them in perfect alignment as he then tacks them in place.
IMG_20190514_105509Viewed from up on deck here is what the finished Hinge Box looks like as it waits to receive the Hinge Arms of the completed Lids in a few weeks.

Hatch Hinge Boxes close upWhich will look like this when done.  The lids will have 15mm tempered glass adhered to them and there are two 20mm ID drains in the bottom “gutters” of the outer Hatch Frame (red here) to quickly remove any water that makes it down between the Lid and Frame.
IMG_20190515_130345Down in the Engine Room/Workshop one additional aluminium detail has been looked after with the tacking up of the hinges on the Engine Room door which completes the Engine Room Enclosure construction and can now be fully insulated and lined with Alucaboard as it waits for the installation of the sea chests and ultimately the massive Gardner 6LXB engine and Nogva CPP propulsion system.
IMG_20190516_173305Speaking of Mr. G as we refer to our mighty Gardner engine, several of you have asked for an update on his status which will have to wait for a bit longer I’m afraid.
IMG_20190517_160918All the other aspects of the build have been consuming all my time to date, but I can give you this sneak peek and confirm that I am now busy with completing the full restoration of Mr. G to better than new condition.  Thanks for your patience and stay tuned for MUCH more in the coming weeks I promise.
IMG_20190516_150902Sticking with metal but changing to copper as in wires and cables, Hilmi our electrical lead continues to string wires throughout the boat, the latest being these gray ones which indicate that they are AC power lines which in this shot are crossing the ceiling of the Workshop and heading for those white cable trays to take them forward……
IMG_20190516_151343……. to these wire trays in the Basement. 

The loop of black 50mm / 2 fuel hose on two of the Fuel Fill/Vents into one of the six fuel tanks is exciting to see as this means they are pressure testing the latest round of work on the tanks and fuel plumbing.
IMG_20190516_151608Such as installing the lids on all the many access ports on each tank. 
IMG_20190516_152123Same is happening for all six water tanks. 
IMG_20190516_151415All these SS studs will either be ground down flush with the tops of the nuts or have acorn nuts threaded on their ends for safety where they will be walked on.
All this metal work is truly beautiful to this beholder but the newest source of beauty is over in the cabinetry workshop here at Naval Yachts so let’s head over there to fully immerse ourselves in this week’s beauty bath.


IMG_20190513_132341I don’t think you need to be a cabinetmaker to appreciate the beauty of the swirling grain and colours of this Rosewood we are using for all the interior cabinetry. 
IMG_20190513_181519These are the first of MANY more panels to come out of the veneer press.  The brown tape is used to hold each seam of veneer tightly together when they are being glued up.
IMG_20190514_105934Each of the hundreds of pieces in this eXtremely large jig saw puzzle of cabinetry requires its own combination of veneer, solid rosewood and solid beech such as you can see in this piece that has just been glued up and is ready to have its edges trimmed and corners rounded prior to being machined for biscuits, dados, rabbets and other joints.
IMG_20190516_104443

Adding plywood to the mix, here we see all four woods coming together for this corner where a solid beech inner block is faced on two sides with Rosewood veneer, one side with 10mm 3/8” thick solid Rosewood and the fourth side glued to the vertical sheet of marine plywood.

BiscuitJointedTee.pngIf you are not familiar with the term “biscuit joint” is a very strong and fast way to glue two pieces of wood together with a small oval “biscuit” made of compressed wood that tightly fits into matching grooves cut into the two joining pieces. 
In our case these joints are mostly used to keep two parts precisely aligned and edges flush as they are glued up and the whole assembly is then held together with other joints and ultimately fastened super solid to the aluminium and wood inner frames of the boat.  One of the great joys I learned first hand while sailing our previous all steel sailboat for over 12 years was discovering how QUIET metal boats are.  Unlike other hull building materials, steel and aluminium hulls don’t flex and move when at sea so there is not the typical cacophony of squeaking wood joints that is typically prevalent in non metal hulled boats.   When you add all the 50mm / 2” thick EPDM foam insulation we have installed you end up with an eXtremely quiet boat.  Subtle differences to some perhaps but this lack of such intrusive noises is a huge part of the beauty I feel when at sea in such boats.
IMG_20190516_104806Here is another example of how some of the wooden jig saw puzzle pieces are joined, this being a half lap joint where two dados or slots are cut half way through each adjoining sheet and then slid together. 
IMG_20190516_104811A bit hard to envision at this point, but Omur our Head Cabinetmaker is putting together the inner framework that supports the king sized bed in the Master.  The vertical sheet to the rear is one half of the large headboard which extends up to the ceiling.
02Lots of details have changed since this rendering but it will help you visualise what you see Omur putting together above.
IMG_20190515_125554A few more details of the cabinetry craftsmanship is seen in this example of how every exposed edge of plywood has this kind of T insert to give the edge that 10mm thick solid Rosewood ….
solid edging on veneer plyrather than typically just being veneered over. 

This is eXtremely eXpensive in terms of both labour and wood but two big reasons we have gone this route.  First is to prevent having any exposed veneer edges which over years of use would end up coming away and splintering. 


Winning Wood sampleSecond being that I am insistent of not having ANY sharp 90 degree corners on our boat!  They must ALL be rounded over as you can see in this quick sample board we made up.  The vertical corner has about 20mm radius and the outer edges you can see on top here are about 5mm radius.
Needless attention to detail some might say but for me, the feel of smooth rounded wood edges is part of the “emotional design” I am striving for and is a very significant factor in the Safe-Comfortable-Efficient trifecta of primary characteristics these XPM boats.

IMG_20190515_125513Carrying my insistence, obsession if you insist, with having rounded edges, I’ve come up with what I’m calling a “quilted” look where two edges join each other, even if they are glued such as this one.
IMG_20190515_125524Another bit of attention to detail if you look REALLY closely (click to enlarge) is how the Rosewood veneer has been applied AFTER the solid Rosewood T edging has been glued and trimmed flush with the underlying plywood. 
Related imageThe MUCH easier way to apply solid wood edging to veneered plywood can be seen in this illustration where you first apply the veneer to the plywood, trim it to size and then glue on the solid wood edging last, then trim and sand the two flush. 

Works well enough but you tend to see the glue line and even the smallest gap or splintering between the veneer and the solid wood edging.  If you look back at the photo of the “quilted” joint above you will see that by overlapping the veneer on top of the solid wood edging and then shaping the rounded corner, the grain of the veneer flows smoothly into that of the solid wood edging.

Again a MUCH more labour intensive detail but Naval’s cabinetmakers and I wouldn’t have it any other way and when you see the results once the final finish has been applied I think you too will agree it was all worth it.
IMG_20190516_152453Continuing with corner details you saw the prelude to this last week as the solid Rosewood was being glued to the Beech block underneath and now this has been machined with a 50mm / 2” radius.
IMG_20190516_181601Ends capped with Rosewood veneer as a small part of this will be seen as you will see as this bed frame is assembled, the 50mm corner will fit into these two hollow cored sides to the dropped ceiling box above the bed, as per the rendering above.
IMG_20190516_181533Just dry fit here but it shows how the two 50mm corner pieces fit with the three sides of this frame.  All those adjoining edges will be rounded over to create that “quilted” look before they are glued up with biscuits.


A few more details on weight saving for those still bearing with me, those three flat sides above may look like they are made of a single plank of solid Rosewood but they are in fact mostly hollow box frame sections that are very light and very stable.  We deposit more weight saving dividends into our weight budget by using poplar cored marine plywood for all the cabinetry rather than Baltic birch marine plywood as it is considerably lighter, more dimensionally stable and has a flatter surface for veering. 

Saving the best for last in this focus on cabinetry corners, here is a peek at how Omur and his crew are creating all solid wood large 100mm / 4” radius corners for all the vertical edges throughout the interior.

IMG_20190517_172448Veneer would have been SO much easier and cheaper but as you know from your home, these corners are high traffic areas that suffer a lot of wear and tear over the years and if these were done with veneer they would show this very visibly and with no real way to repair.   
Instead all corners and edges on Möbius are solid wood which will stand up to this wear and tear indefinitely and will be relatively easy to repair any damage back to like new for the very long life these XPM boats will surely have.

IMG_20190517_172430As you can make out here, three lengths of solid Rosewood have been cut with edged mitered at 30 degrees and biscuit glued together to form a 90 degree corner. 
Gluing the three boards has to be done in two steps as trying to clamp all 3 at the same time would not create perfect glue lines and then once all the glue is cured the outer surface is machined to the 100mm radius followed by copious amounts of elbow grease with a radiused sanding board.

IMG_20190517_172456Knowing what went into creating this corner will help you understand Omur’s hard earned look of exhausted pride as he holds up this first prototype of such corner construction that he and his team will now use for all the many other corners onboard XPM78-01 aka Möbius.

I may not be as exhausted but I am certainly just as proud and happy as Omur and his talented team of cabinetmakers are.  And they are just getting warmed up so stay tuned for much more from all the talented people on Team Möbius as we continue to bring you these weekly progress updates.

Short but hopefully sweet video here is your video summary for this week.  Will try to do more next week.

As always, thanks for following.  Like, subscribe and most importantly add your comments, suggestions and questions in the “Join the Discussion” box below.

U Wood 2!

U Wood 2!

This week’s progress building our beloved MV (Motor Vessel) Möbius and XPM78-01 here at Naval Yachts reached another exciting milestone with the cutting of the first wood being used to build our interior cabinetry and furniture.  We are VERY excited about this and as per the title we think “You Wood Too!”  Not that the work on all things metal and mechanical aren’t exciting as they continue to progress very well too, but this most recent deep dive into designing and now starting to build the interior of our new home and boat has us particularly excited and wanting to share it with you so please join us as we dive into the latest progress in designing and building mv Möbius.

IMG_20190509_140436As you may recall if you read the previous post “Miss Mobius World Wood Pageant” we have chosen to use Rosewood for all our interior woodwork and so it was a very exciting day when the first truckload of solid and veneer arrived from the lumberyard near Istanbul. 
With different languages and species all this wood is from the Dalbergia family and goes by several names including Santos, Palisander, Pelesenk, African/Burmese Blackwood and (your choice) Madagascar/Brazilian/Indian/Honduran/Yucatan/Amazon/Burmese Rosewood.  You may be interested to know that these woods are called Rosewood because they give off a rose like scent when being cut and worked so I will borrow from the bard’s astute observation that “A rose by any other name would smell as sweet”, add my own “and be as beautiful” and from here on in I will simply refer to this as Rosewood.


IMG_20190509_140503The photo above was taken as the protective wrap was first pulled back to unveil the stacks of hundreds of flitches of Rosewood veneer quickly followed by the same reveal of these planks of our solid Rosewood.  While we had spent a LOT of time searching for and choosing this wood it still took our breath away with the reality and beauty of this wildly varied colours and swirling grain patterns. 


Christine and I were still in Florida being Gramma and Grampa so Dincer had flew up to Istanbul to personally select the specific batches of veneer and solid Rosewood for us and as usual he did a masterful job of choosing the just right Rosewood for us.


My dear friend Eileen Clegg once called me an “extremophile” which I took as a compliment, and with Möbius being the first of Naval’s XPM eXtreme eXpedition Passage Maker series of boats it seemed only fitting that we would have sought out a wood with such eXtreme ranges of colour and grain.  The only thing more eXtreme than the beauty of Rosewood is its price but Christine and I may well spend the rest of our lives living aboard Möbius and want to be surrounded by beauty every one of those days so this was an easy decision to make given the infinite amount of joy it will provide for us and others who join us aboard.


IMG_20190510_111038

This photo shows how the cabinetmakers have unpacked the first four of that stack of wide strips of veneer known as flitches shown above into matching layers after cutting off any splits or damage at their ends. 

Is this Beauty in the eXtreme or what???
IMG_20190509_180120As with most other facets of boat building Naval does all their cabinetmaking in house which includes doing all their plywood lamination so these Rosewood flitches will soon be matched up on either side of marine birch plywood and be pressed and heated in this large hydraulic laminating press to create the finished veneer panels.  You will see this fabulous bit of kit in action in the upcoming weekly updates.
IMG_20190509_175616As beautiful as the veneer is the solid Rosewood more than shared the spotlight as you can see here with these first four 25mm / 1” planks to emerge from their own stacks off the truck.

The very large staff of professional cabinetmakers, which I will be introducing to you over the coming weeks, seemed to be equally as excited and impressed by the opportunity to start transforming this Rosewood into furniture and cabinets for Möbius. 

You Wood too right?
IMG_20190509_140909Those first planks were soon coming out of the table saw and shaper as these T shaped strips which will next be glued to all exposed edges of the veneered panels.  This solid Rosewood edging is at least a 10mm / 3/8” thick which enables further shaping and ensures that none of the veneer edges are exposed to any wear and tear over the years.
IMG_20190509_175541Panels which will have all four sides exposed when finished on things like drawer fronts have these solid Rosewood T’s glued on all four edges with mitred corners such as the one on the far left here.  All the outer corners of these T edges will be rounded over with a 3-5mm radius to make them very easy on your hands and very luxurious in their looks.
IMG_20190509_141011Another technique for creating the large 50mm/2” Radius external corners and reducing the amount of Rosewood required on things like vertical cabinet edges, corners of the bed frame, etc. begins with gluing these triangular shaped lengths of solid Beech, the white wood here, to lengths of solid Rosewood.
IMG_20190509_175531Why? might be a common question so I grabbed a piece of scrap wood with a 50mm Radius on the bottom side and made that horizontal pencil line to show how the Rosewood portion of the glued up piece on the bottom left will be machined with that large radius surface being all Rosewood and the inner triangle of Beech providing the a large surface area for the adjoining panels to be glued in place and be hidden in the joinery on the inside. 
IMG_20190510_130932Once the glue has cured the next day and operation is to machine these laminated lengths of Rosewood and Beech …….
IMG_20190510_130940…… into this shape and you can now hopefully see how this creates the two wide flats at 90 degrees to each other to form the large vertical corners on cabinets and corners and then have the full 25-30mm thickness of Rosewood to form the rounded outer corner.


I’ll be able to show you this in much more detail in the coming weeks as the cabinetry progressed so let’s leave the cabinetmakers alone for a bit and go back aboard Möbius to see how things are progressing there.


IMG_20190510_130018The “Sparkies” as our brilliant Kiwi (New Zealand) designer Dennis would call the team of electricians who are growing in number aboard Möbius, are now busy running literally nautical miles of wiring throughout the conduits and wire trays and have setup shop in the SuperSalon to do the cutting and labeling of all the individual runs of wire.
IMG_20190510_125343If you look in the background of the picture above (click to enlarge any photo) or in this close up shot you can see some of the runs of flexible conduit going up the inside of the vertical SuperSalon window mullions which are soon filled up with the wires for devices up in the ceiling of the SuperSalon and the SkyBridge.
IMG_20190510_125323Each length of wire is labeled with the temporary tubular yellow labels you see here.  With hundreds, perhaps thousands of wire end connections to make, this labeling is key to making it faster and clearer for the Sparkies to know that the right wire is going to the right switch, light or circuit breaker. 
Before the final wiring of each connection is done each wire will be cut to the just right length and additional labels will be heat shrunk to each end of all wires for future reference whenever someone, aka ME! is doing any modifications or maintenance of any of the eXtensive electrical systems aboard Möbius.


IMG_20190510_125536

Down in the Basement we see that the “Poopsmiths’ ** aka plumbers in Kiwi speak, have been busy starting to install the runs of Vetus Sanitary hose for all the Grey (shower & sink) Water and Black (toilets) Water tanks, pumps, drains, etc. 


** Full list of such wonderful Kiwi slang words here for those of you interested in “dropping your gear’ and go “full tit” to be fully “home and hosed” when it comes to speaking like a native down under.  I hope this doesn’t’ come across as rarking you up or pack a sad for too many of you and if so the next drink is my shout but this offer is only good at sparrow fart.


IMG_20190510_105510Those of you who have been following this blog for awhile will recognise this and for the rest of you this is one of the hatches which I’ve designed and Naval is is now building in house.  The little army of aluminium boxes on the right are the hinge boxes which provide the support for the SS hinge pins that slide through the 8mm / 5/16” holes in their sides.

Hatch Hinge Boxes close upTurning these boxes transparent in the 3D model of these hatches (click to enlarge) will show you better how they work.  Everything but the Rosewood inner liner is all aluminium but I have coloured the Lid Blue and the Frame in Red he blue for added clarity and you can see how the Blue Hinge Arms which are welded to the Lid, extends into the Hinge Boxes under the deck and rotate on the white SS 8mm diameter hinge pins. 
I used one of my favorite CAD tools, Autodesk Fusion 360 to design these hatches and here is a little animation Fusion enables me to create which I hope will show you how the hatch works.



Hinge ArmOne of the most rewarding aspects of designing and building your own stuff is when your designs are transformed into reality and here is my most recent example.  This is what the Hinge Arm you’ve seen above looks like as a component within the Fusion 360 model.
IMG_20190508_154537And here I am holding that very same Hinge Arm after Uğur has cut it from a solid block of aluminium. 
IMG_20190508_154548We decided to create a few prototypes of these hatches to fully test out my design in the real world and here is one of the prototype assemblies of the Hinge Arm assembled within the Hinge Box on a temporary threaded hinge pin.
IMG_20190510_124853Hinge Arms tacked to the Lid and Hinge Boxes tacked to the outer Frame.
IMG_20190510_124907A quiet ”Open Sésame” and Voila! it works!  The hatch opens fully to the 120 degree angle I wanted as the Hinge Arms come into contact with the inner edge of the cut-out in the outer Frame where the Hinge Boxes attach.


After a few tweaks with the prototype hatches to get these hinges working and positioned just right we were ready for the critical step of welding the Hinge Boxes to the actual Hatch Frames that have been welded into the decks on Möbius.


IMG_20190510_162632As you can see from the photos and models above, the two Hinge Pins have to have their centerlines precisely aligned in order for the Lid to open smoothly so Yiğit and I designed up a jig that Uğur and Nihat could use to hold each pair of Hinge Boxes in just the right position under the deck plates and up tight against the outer Frame surfaces and tack the Hinge Boxes in place.  You can see the aluminium plate part of this positioning jig in Ugur’s right hand here and  It worked just as we hoped. 
IMG_20190510_162642I forgot to take a picture of the jig itself so what you can’t see but can hopefully imagine is that there are two arms welded to the edge of that aluminium plate which exactly replicate the Hinge Arm positions and have matching pipes for the Hinge Pins to go through.  So Uğur slides these two arms on the jig into the rectangular openings you saw above in the outer Hatch Frame and then holds each Hinge Box in his left hand and slides it over the arms of the jig and inserts an 8mm pin through the holes in the Hatch Box and the jig. 


Takes longer for me to type this than it did for Uğur and Nihat to tack the Hinge Boxes in place and hope this all makes some sense to most of you?


IMG_20190507_111037While Uğur and Nihat were busy working up on deck, our awesome Master Welder Sezgin was busy down on the shop floor under Möbius finishing up the welding of the Hatch Lids. 
IMG_20190507_122930And the pile of finish welded Lids piled up quickly.  In case you are wondering, he tacked two lids together to help hold each Hatch Lid assembly in alignment and prevent them from warping or moving as they were welded up.  Then the tacks are ground off to separate each Lid and the Lids are cleaned up and prepped for the last bit of welding the Hinge Arms to the Lids which is perhaps the trickiest and most important step to ensuring that the Hatches open, shut and seal just right. 
Once the Lids have their Hinge Arms welded on they will be sent off to the glass supplier to cut and install the 15mm tempered glass to complete the Lids and I’ll cover that as it happens in the next few weeks.

And as Porky the Pig used to say “Th-th-th-th That’s All Folks!”  At least for this week.  Hope you are continuing to enjoy and possibly even get some value from these weekly progress updates and I look forward to your comments, questions and suggestions you leave in the “Join the Discussion” box below.

Thanks!!

– Wayne




Möbius Walkthrough Video Tour May 2019

Möbius Walkthrough Video Tour May 2019

It was a 4 day work week for most people here in Turkey with May 1st being the big  “Emek ve Dayanışma Günü”  or “Labor & Solidarity Day” public holiday also known simply as “May Day”.  Very similar to the holiday around this time in many other countries.  With this also being our first week back after our great two week trip to Florida for some fabulous family and friends time and me sporting my semi annual haircut we thought it was a good opportunity to put together an updated and highly requested video walkthrough tour of Möbius to summarise all the progress since the last video tour.  First a few photos of the progress this first week of May and then the video tour at the end.  Let’s get started!

IMG_20190429_103525The 10mm thick Hatch Lid plates, just out of the CNC machine, were next up for the in-house fabrication of all the deck hatches so the prep work began on welding the inner frames to the Lid plates.  
Open Hatch with DrainsIf you have not yet read about these hatches I designed in previous posts, here is a quick rendering of the complete hatch assembly.  The Lid is in Blue with 15mm / 5/8” thick tempered safety glass adhered on top that sits flush with the deck surface.
Hatch Hinge Boxes close upThe hinges are hidden below the decks to make for an even cleaner appearance with no obstructions on the deck.
IMG_20190501_102700Here is a stack of 4 of the Lid plates with the edges chamfered at 45 degrees where the flat bar of the inner frame will be welded and then all the edges which will be on the inside of the hatch lids all radiused.  The 15mm glass will be adhered to the opposite side.


IMG_20190429_103542Nihat and Uğur prepping the next pair of Lid plates.
IMG_20190502_101404The four large radius corners are carefully formed in the 8mm / 3/8” thick flat bar that creates the inner frame of the Lids is fitted to be perfectly flush with the outer edges of the Lid plate, clamped and tacked in place.  The ends are trimmed to the just right length and welded.
IMG_20190503_105845And in no time all ten hatch lids are stacked up awaiting Sezgin to finish weld them all around.  In the coming weeks these will be cleaned up and prepped for attaching the hidden hinge arms to the Lids and fitting them to the hinge boxes welded under the decks so stay tuned for more as the hatches progress.
IMG_20190503_105925Having pretty much finished gluing all the miles of EPDM insulation to all the interior aluminum surfaces, the seemingly tireless Mummy has now shifted to applying all the thick cloth backed AL foil to the lower sides of the hull Inside the Workshop.  This is the same cloth backed foil covered all the walls and ceilings in the Basement with that you’ve seen in previous posts which produced a fabulous way of covering the EPDM in areas where it will be left exposed to protect it from wear, help reflect light and be easily cleaned and maintained. 
IMG_20190503_184108In the Workshop we are using the same foil to cover the EPDM that extends from the top of the long workbenches down to where the EPDM stops at the floor/bilge areas.
IMG_20190503_184045This is the opposite “wing” of the Starboard side of the Workshop which runs down the side of the Engine Room enclosure walls you see here on the left.  The white Wire trays are all mounted up high on the hull on both sides and will soon be filled with wires, hoses and cables for all the electrical and plumbing runs.  The 500L Day Tank will be mounted at the far end up against the WT Bulkhead where the Guest Cabin begins.

Demir Yigit Mert May 4 2019Progress also continues in the Dinç family where Dinçer, the co-founder of Naval Yachts, and his wife Nesli are kept eXtremely busy raising their new three boys, twins Mert and Yiğit
Demir kissing Mert May 4 2019and 3 year brother Demir, who as you can see is loving being their big brother.


But enough with the static photos and text and on with the promised video walk through tour. 

We put up the previous walk through tour in this “Skinning the Skeg” blog post back in October 19t last year (2018) and you click on that for a review if you missed it.  Or you can go direct to this link to the YouTube video of just the Walk Through video tour if you prefer.  This was one of our most viewed posts and we’ve received a lot of requests for more video and another update so here it is. 

With such an incredibly diverse collection of followers there will be too much detail or it is going too slowly for some of you so I will put in visual breaks as we move from one area to the next with renderings of each area of the boat to help you visualise how these areas will look when completed.  I hope this will make it easier for you to jump around within these longer videos if it any area is getting into too much detail.

We will start with a tour of the interior spaces beginning with the forward Master Cabin and work our way back all the way to the Workshop/Engine Room area and then show you around up on the deck and down on the shop floor in a second video. 

WALKING TOUR of INTERIOR SPACES as of May 4, 2019:

This video is much longer than usual at about 27 minutes so grab a good beverage and a comfy chair before you hit Play.  With SUCH a wide audience here there may be way too much detail in some places for some of you so remember the great thing about video is that you always have the Fast Forward key!

WALKING TOUR of EXTERIOR & DECK as of May 4, 2019:

Second video, about 26 minutes total, is a Walkthrough of the exterior spaces from the Aft Deck to the SkyBridge to the Forepeak and a last look at the Bow Thruster tube and new Hatch lids that are the most recent additions.

Please let me know how well these videos are working for you, suggestions for changes, additions or any other ways to make this all more interesting and valuable.  I’d love to honour the many requests for more videos and more on the Mobius.World YouTube channel but I have to prioritize my time and attention to the build which fills about ten hours of my day six days a week so I’m challenged to have the time to do all the video editing on top of this but will do my best to provide more video as the build progresses.

Thanks SO much for joining us and hope you enjoy.