Christine and I are in Italy for a combined anniversary celebration in Napoli last weekend and now a chance to catch up with dear friends on their catamaran as we sail around the island of Sardinia. While I may be MIA the rest of Team Möbius, the ones who really matter, were hard at work back in Antalya and they made great progress in all the various facets of work from cabinetry to electrical, plumbing and aluminium. When the cat’s away the mice really do play!
So with great thanks to our Möbius Project Manager Yiğit for taking on extra duties as photographer while I’m away I am delighted to bring you this week’s progress update and so let’s jump right in.
Nihat on the left and Uğur continue to work their way through the diminishing list of aluminium jobs to complete and those of you with sharp eyes and memory you can see evidence of one of those jobs in this photo. Can you see it? How about if I take you up on the foredeck and move in a bit closer?
Correct! They are building and fitting the aluminium stanchion posts. Further back on the Port/Left side deck where the Pilot House ends, you can see how the stanchion posts join together with the pipe railings for the side gates to provide eXtremely safe and sturdy protection along all parts of the deck to make sure we always stay onboard. Moving forward along that Port side deck you can see how the stanchion posts continue forward and then tie into the pulpit railings on either side of the bow.
All the pipe for the stanchions, pulpit, pushpit and gates are made from 40mm / 1.6” OD pipe with 6mm thick walls which are a snug fit into the socket pipes which are welded all the way through the 10mm thick Rub Rails down each side. To eliminate any wobbly and prevent any corrosion between the stanchion and socket pipes, black Delrin bushings you can see at the base of each stanchion have been machined and press fit in place.
There will be domed aluminium caps atop each stanchion which are now being machined along with the short aluminium bushings that will soon be welded into those three holes in each stanchion to provide a smooth surface for the Dyneema lifelines to run through without chafing.
Dyneema is a synthetic fibre line which is stronger than the typical stainless steel stranded wire used for most lifelines and it is lighter and much easier to see evidence of weakening over the years whereas SS wire usually hides cracks or faults until it lets go. Also much nicer on the hands and no chance of any “meat hooks” as we refer to an individual strand of SS wire when they crack and break off leaving a nasty hook to catch and cut your hands.
The stanchions and railings are 1m / 39” above the deck which is much higher than most boats but very much by design for the XPM boats for added safety. If you were to be thrown into lifelines at this height they would catch you well above the waist whereas the more typically shorter lifelines are below the waist and can result in flipping you overtop the lifeline and overboard. Our primary Person Overboard strategy is simple; don’t! High lifelines are one of the best ways to ensure we stay onboard at all times. If you do go over the side it would most likely be Ciao for you because it will happen at O’dark Thirty in very nasty weather. The scenario doesn’t play out much better and often much worse if you are clipped onto the boat with a tether as you end up trapped on the end of your tether partially submerged and nigh on impossible to be brought onboard. Hence very high and very strong lifelines and railings.
Dropping down to check out the Basement we find more evidence of Uğur and Nihat’s handiwork where they are fitting the watertight AL plates which seal off the coffer dams for the active stabilisers on each side of the hull. This coffer dam with the Basement exiting Sea Chest is on the Starboard/Right side and the Port side is shown below. Coffer dams are as the name implies, there to increase the safety factor in the rare event that an active stabilizer fin strikes something solid at speed and tears out or through the thick hull plates. While the protruding fins do introduce this possibility of being struck it is quite low, Safety is top priority for XPM boats so we design and build accordingly, hence these coffer dams. With the eXtreme plating thickness on all parts of the hull and all the welded in support frames for the stabilizer hardware the probability of breaching this area and creating a significant leak is eXtremely low but never zero so these strong cover plates are bolted and sealed in place with gaskets. Inside each coffer dam there is a sensor connected to an alarm system that would let us know if any water did collect in the bottom.
As you will see a bit later in this blog, Christine and I have chosen to use passive rather than active stabilizers so these coffer dams will be empty but still very well sealed. Throughout the design of this first XPM we have done our best to “future proof” these boats as much as possible by allowing for choices such as active/passive stabilizers by including everything needed for the installation of any of them within the initial design and build. In this case, if/when we or future XPM owners chose to install active stabilizers the hull and coffer dams are all ready for a relatively fast and cost effective installation.
Looking up overtop of the Basement Sea Chest Cihan and his plumbing team continue running more of the various pipes and hoses White hose against the aft Basement WT Bulkhead is sanitation hose carrying Black Water from the heads to the holding tank. The black lines in the foreground on the ceiling are part of the AirCon system with 20mm/ 3/4” PPR pipes (similar to PVC) wrapped in thick black EPDM insulation which carry the cold water from the chiller system to the individual air handlers in each cabin and the SuperSalon.
Above the Basement ceiling/SuperSalon floor we find more white sanitation hoses being installed. Left is the Vent box with the white being the vent for the Black Water tank in the Basement and the black hoses being vents for the fuel tanks. On the right is the Fuel Fill box which also has the two white sanitation hoses for pumping out the Black Water and Gray Water tanks though most of the time we pump out our Black Water through the Sea Chests when far enough out at sea.
Up forward on the Port side of the Master Cabin Head/Shower we find more plumbing progress with the installation of the Hot and Cold domestic water manifolds with all these red handled PVC ball valves.
These ball valves also make the transition from 20mm/ 3/4” PPR pipe which are the primary supply lines bringing hot and cold water from their sources to the 15mm/ 5/8” PEX tubing which connect to each of the hot and cold water consumers; sinks, shower, toilet, bidet. We also use the cold water manifold for the fresh water washdown pump in the Forepeak on the other side of this WT Bulkhead wall. The black EPDM insulated line above the manifolds is the Domestic Hot Water DHW loop which runs the length of the boat to deliver hot water to every hot water consumer as soon as you turn on the tap eliminating the usual need to wait for the water coming out of the sink/shower tap to get hot and wasting a considerable amount of water in the process. Efficiency is one of our four primary design principles so we seek out every possible way to increase the efficiency of all systems on board these XPM boats.
Not always as visibly evident rest assured that Hilmi and his electrical team continue to install more wire trays and fill them with more and more nautical miles of gray AC and black DC wiring. The black flex hose on his right is conduit for the wires which run up through the window frame mullions in the SuperSalon with other wiring in the horizontal white perforated trays just above the floor.
Looking up in front of where Hilmi is sitting you can see how he has also installed trays on the underside of these frames where the outer side decks run. Vent Box above. More trays at the aft Starboard/Right side end of the Guest Cabin are starting to fill up with wires and clear water hoses at the bottom. Moving aft to the Starboard/Right side “wing” of the Workshop alongside the Engine Room Enclosure wall Nihat and Uğur have wrestled the Day Tank aboard sporting its mounting tabs and ready to be test mounted to the WT Bulkhead at the far end. Matching mounting tabs have been welded to the ER Enclosure wall and threaded bosses welded to the vertical T frames on the WT Bulkhead. With the mounts installed and Day Tank successfully test mounted, Mummy and his insulation team can apply the thick AL foil overtop of the black EPDM insulation prior to installing the Day Tank and the AlucoBond panels.
One of the most eXciting projects this week is THIS! Uğur and Nihat started to fabricate the paravane A-Frames. As you might guess, the pipe on the right is the main “boom” and the two on the left will be the angled tension pipe that attaches to the tabs just below the end of the main boom. Hopefully this rendering from our Paravane design testing phase will help more than confuse and give you a better sense of the components of the overall Paravane system. ** Important to note that this rendering shows the hinged A-Frames in both their “up” vertical stowed position and their “down” or deployed position. Similarly there are multiple images the one paravane, sometimes called “fish” or “birds” as we were analyzing different positions, depths and angles.
If these Paravane A-Frames look familiar to you it is likely because many commercial fishing boats use the same system and use them daily in truly eXtreme conditions to help keep their boat decks as stable as possible to enable them to work safely and at all in such conditions.
We went through many, many iterations of the whole system, particularly the rigging and the final design is considerably different than this early design with the green boom lift now going out to the end of the booms and the booms being extended to be over 7m/24’ long. To the uninitiated the rigging may look a bit intimidating and complex but for us two sailors, and really to anyone after a few uses, it is a very simple and straightforward setup and we have simplified is MUCH more in the final design. I’ll go into those details in future posts as we install the Paravane rigging.
When deployed in the water, each paravane runs about 5m/16’ below the surface of the water and their shape is such that they “fly” through the water with a slight downward pull. When the boat rolls towards one of these “fish” they dive down lower and provide resistance when the boat tries to pull them back up.
Here is a close up of the outer end of the A-Frame boom with thick aluminium tabs and gussets let into the equally thick walled 10mm / 3/8” pipe which provide all the attachment points for lines and the angled pole of the A-Frame which you can see in the upper background. Once everything is all test fit to be just right every joint will be welded through.
Paravanes are somewhat similar to the pole a tightrope walker uses. Having one of these paravanes on each side provides two opposed points to help us remain “balanced” and goes a long ways towards countering any forces trying to roll the hull along her lengthwise axis when conditions warrant. While the forces within this system can be very high at times, one of the relationships you come to understand is that if a hull has lower initial stability, takes less force to cause it to roll, it takes equally less force to cancel out or resist this roll. As counterintuitive as it first sounds, lower initial stability is also a positive factor in terms of safety at sea and greater overall stability of a boat so these paravanes take advantage of this relationship to help keep the boat more level when Mother Nature is trying to cause her to roll.
At the other end of the A-Frames these bits of 25mm / 1” thick AL create the hinged attachment points connected to their matching 50mm / 2” thick other halves welded through the Rub Rails which transfer all the loads directly to the inner framework of the hull. To be clear, active stabilizers reduce the roll to a greater degree when underway but they come at a “cost” in both complexity, drag, maintenance, fault tolerance and expense so for us former long distance sailors we think that passive paravanes will be a better fit for us and our use cases. All yet to be confirmed by real world experience of course so stay tuned for that after we launch and start putting all these systems to the real test out at sea. We will extend these real world sea trials gathering data and experience once we start heading West across the Med and then crossing the Atlantic next summer. Such in person testing on multiple ocean crossings and other situations which will enable us to make much more informed decisions on the changes and improvements we want to make in the future including whether we would like to add active stabilization in the future. Stay tuned for much more of that.
Finishing up this Weekly Progress Update with the Cabinetry team they have been busy installing the grids for the walls in the Guest Cabin. You’ve seen the technique used in previous posts which is to glue solid wood spacer blocks through cut outs in the multi layered acoustic insulation to the underlying 5mm AL plate. The lattice style wall grids are then glued and screwed to the ends of these wood spacer blocks. All the wood is thoroughly sealed with multiple coats of white epoxy paint and provide nice smooth non porous surfaces which are easy to keep clean and help with one of our other fundamental principles of low maintenance.
If you look closely on the inside of second horizontal grid off the floor you can see how the grid is also used to mount perforated trays to carry hoses, pipes and wires across the Cabins. Omer continues this way working his way across the aft WT Bulkhead which isolates the Guest Cabin from the Workshop and ER. He soon has the grid completed surrounding the WT door at the end of the corridor outside the Guest Cabin where you can enter the Port/Left wing of the Workshop. Spinning around to look forward and diagonally across the Guest Cabin to the Starboard side Omer has picked up where he left off last week by mounting the grids where the Cabin transforms into the Galley cupboards with the stove and oven.
As we covered in last week’s update this transition and grid has aluminium stepped frames to span the offset area between where the Galley floor ends and the massive aft frame begins.
Zooming in on the far end to better see how the stepped grid as it clears the fuel hoses. The blue clamp is clamping the grid to the stepped aluminium frame hidden behind. If you look closely (click to enlarge any photo) at the upper right corner of the photo above, you can make out this outer 50mm/ 2” L bar. That’s it for the week that was August 19 to 23, 2019 and all thanks to everyone on Team Möbius with an extra shout out to Yiğit for taking all these photos for your intrepid reporter who is now sailing past several of the worlds largest and most impressive “GigaYachts” (Super no longer applies) here in Sardinia including the Maltese Falcon, A and Dilbar. I’ll create a bit of a photo summary of these boats for you next week.
Everyone at Naval Yachts had a well deserved break to celebrate the big four day Kurban Bayramı holiday as families gathered to enjoy time with each other and friends and LOTS of great food. So a short blog update for this two day work week. As the title is meant to suggest most of the work the past two days has been on installing the wood grids on the walls in the Master and Guest cabins. These grids anchor all the walls and some cabinetry to the aluminium bulkheads, floors and ceiling frames and provide space for acoustic insulation and any wiring and plumbing which needs to travel through these walls. Let’s go check it out onboard XPM78-01 Möbius.
For orientation here is a quick render of the Shower and Head are in the Master Cabin. As we saw last week all the cabinetry along the Starboard/Right side of the Master Cabin and the forwardmost wall and door into the Head/Bathroom have all been fitted. This week the wall and door which sit alongside the Vanity sink cabinet you see here have been taken back to the Cabinetry workshop for final sanding and the new addition is this short laminated wood section of the shower wall that joins the glass wall to the hull sides.
Now Omur and Selim move on to putting in the grid on the other end of the Master Cabin where the WT Bulkhead between the Master Cabin and the Basement forms the aft wall. The white acoustic insulation is cut away and small 40mm/1.5” solid wood blocks are adhered to the underlying aluminium plate and then the lattice grids are attached to those blocks.
The grid is made light and strong using lightweight marine plywood and this tongue and groove construction with these triangular gussets in each corner. These grids create the foundation layer for attaching the finished panels using FastMount snap in connectors and a similar type grid will go on the ceiling as well. Where needed the spaces in this grid can be used to run wiring for wall switches as well as plumbing in a few places, but almost all wiring and plumbing is routed along the hull sides in dedicated trays.
For those that didn’t see it last week, the grids are fastened to the underlying aluminium plate with solid wood blocks that are adhered to the aluminium with industrial adhesive (Sikaflex) which protrude through cut outs in 3 layer acoustic insulation you see under my thumb here. Moving aft to the Guest Cabin & Christine’s Office we can see the whole process of installing the wall grids. Omer has built the lattice grids in the Cabinetry shop and brought the first one aboard that goes on this short section of wall at the end of the Guest Cabin Head. He starts by laying out the grid pattern for all the attachment blocks. Soon has all the blocks glued in place….. — checked to be sure they are all on the same plane using the laser level and they are now ready to be sealed with epoxy paint. Aluminium and Cabinetry teams meet as Uğur (right) and Nihat (partially hidden) arrive to weld in the aluminium step framing that will help support the cabinetry, marble countertops, stove and oven at the aft end of the Galley. This intersection between the Galley on the upper SuperSalon level and the Guest Cabin below takes awhile to visualise and this GA plan view will help. If you compare the layout of the Galley in the upper view of the SuperSalon with the Guest Cabin below you will see how they overlap where the aft countertop with the induction cooktop and Speed Oven extends a bit into the upper space of the Guest Cabin. Here’s a reminder render of the Galley looking aft and the Guest Cabin is below those big aft windows. If you study the upper left area in this render of the Guest Cabin you will see how this intersection works with the Oven and cabinetry from the Galley forming the step down from the ceiling with the bookcase underneath. With those visual gymnastics you can hopefully now see how this all works with the aluminium step bracing now in place here. Once the aluminium step frames were tacked in place Omer cut the slots in the upper edge of the grid and slid it in place for a test fit. Looks good, Nihat and Uğur double check their aluminium framing and Omer checks the grid and everyone is happy. Omer soon has all the grids attached along this wall and puts on another coat of white epoxy to seal the wood completely. Here is what it looks like from the upper Galley area looking aft and down into the Guest Cabin. The Galley cabinets will be built into this area with the aft countertop setting atop the uppermost aluminium step here. How if you look back at the renderings above of the Galley and Guest Cabin you will see how this busy complex intersection all comes together. That is where things are at when we finished up yesterday (Friday Aug. 16, 2019) and we’ll pick up from here in next week’s progress update.
I will be reporting on all that from afar mind you as Christine and I are taking time to go celebrate our anniversary with a few days in beautiful Napoli Italy and then an overnight ferry ride over to Cagliari on the island of Sardinia to get in some long awaited time with very dear friends and family on their 50’ catamaran “Wicked”.
So I’m with my Beautiful Bride and typing this from the comfort of the very nice Turkish Airlines lounge in the brand new IST airport. A very nicely done airport and while this lounge doesn’t have all the multi levels of the famous TA Lounge in the old IST airport it has even more individual cooking and food stations, over 20 and I lost count each one custom cooking and preparing pretty much anything you can imagine. One of my new favorite airports for layovers to be sure.
Not to worry though, Yiğit will be keeping us updated with lots of photos and daily calls, texts and Emails so I will be able to post a regular weekly update next weekend as everyone on Team Möbius continues to apply their skills and experience to this awemazing build process creating our Goldilocks just right, just for us, XPM boat.
Everything continues to heat up here at Naval Yachts with hot +40C summer days and lots more progress with the building of XPM78-01 Möbius. Onboard Möbius the Cabinetry team, Aluminium team and the Plumbing team continued from where we left off last week and in the Engineering/Design office lots of progress with Interior Design work, choosing materials and working out construction details and 2D drawings. Welcome aboard and let’s go check it all out.
Let’s start in up front with the work on the Head/Toilet and Shower in the Master Cabin with some quick renders from our awemazing Interior Designer Yesim. This is what you’ll see when standing beside the bed just after entering the Master Cabin. The two outer walls of the shower are solid glass and will be etched with an artistic pattern our talented and dear friend Sherry is busy designing for us. Cupboards for clothes, washer/dryer are on the Starboard/Right side which you’ve seen being built in previous posts and this week the Vanity Sink at the far end was completed.
Seen from above with the deck removed you can see a bit more detail such as the two big hatches above the Vanity and the Shower, the seat in the shower and the sink in the Head area. We are going with an open walk through into the shower with a clear glass panel going up from the sink counter to just below the hatch opening to allow air and light into both the Head and the Shower areas. Removing the door and the wall beside the Vanity sink gives us a better view of this whole space. There will be a “shower tower” diagonally mounted in the far corner of the shower and the seat will be done in either teak or rosewood. In the Head there is an iridescent blue/black countertop mounted sink to match the one in the Vanity with hers/his mirrored medicine cabinets in the side wall and the VacuFlush toilet/bidet on the far right. All the interior walls, ceiling and floor of this whole space will be built in place using fiberglass panels and hand laid cloth to make the whole unit fully sealed with no joints. Production boats and homes would make this as one piece in a mold and then lift it in place in the boat before the deck goes on. However as with all the interior cabinetry we wanted to bring all the interior components into the already welded up boat and fasten it all solidly to the aluminium frames and stringers.
Christine is busy hunting down some tiles to add a bit of colour and style to the interior and check out the sinks she found for here and in the Vanity. This rectangular one will go on the counter in the Head.
And this oval shaped one will go in the Vanity.
These are very unique sinks made from solid tempered glass that is about 20mm/ 3/4” thick with hand painted patterns on the outer surfaces with great depth and sparkle when seen from above. Matched up with our aquamarine colour scheme for things like the Horizon Line throughout the boat and 1seemed like the Goldilocks just right, just for us sinks. Back onboard this is about where we left off last week when Omur and Selim had the Vanity Sink cabinet roughed in place and the first wall of the Head/Bathroom positioned. This is where the oval glass sink above will be mounted. Matching cabinetry details throughout with these Horizon Line/Hand holds and well radiused edges on all the solid Rosewood. Back in the Cabinetry shop Ömür is putting together the medicine cabinet that will be mounted above the Vanity Sink. Dado/groove you see in the bottom edge for the LED indirect lighting. Ömür’s ever focused eye checking out the inner details before taking this onboard Möbius …… …… to fit it in place up against the Forepeak WT Bulkhead. The white epoxy painted grid in the background is affixed to the aluminium plate of the WT Bulkhead with epoxy painted wood blocks and provides the foundation for the cabinets such as this Medicine Cabinet to be screwed in place for now. With the Head wall removed you can see how the Vanity Sink cabinetry ties into the Starboard side cabinetry and how the overhead hatch will really light up this area. Yesim and Harken (middle) our gifted 2D cabinetry drawing wizard join Ömür and myself onboard to go over the many intricate details for this busy space with plumbing, wiring, cabinetry, doors, in floor heating, drains, water supply, fuel tank access and the list goes on. Every day is filled with hundreds of such details and decisions which keep all of us on our toes and at the top of our game. Here for example we are confirming the location of the hollow channel inside the door jamb in the foreground where the wiring will come down to the light switches below Harken’s elbow.
(for those wondering, my hand is the upper left to keep out the lens flare from the big hatch over the Shower.) With those details worked out for now Ömür screws the marine plywood backing that form the end wall of the Head. A similar construction will take place next week on the hull side walls and then all these plywood surfaces will be laminated with fiberglass sheets to form the continuous walls, floors and ceiling surfaces. Ömür and Selim move their attention to the aft Port corner of the Master Cabin and starts to attach more of those solid wood blocks to the aluminium plate behind the white acoustic foam insulation.
Next day when the adhesive has cured the grid framework can be screwed in place. Zooming in closer you can see how the grids are constructed with tongue and groove for the triangular braces and keeping this gridwork all eXtremely light yet strong. When the plywood panels are mounted on top of the grid it will create another layer of insulation of trapped air…… …….. that will sit atop the three layers of varying density acoustic insulation you can make out under my thumb. If you look closely (click to enlarge any photo) you can see the thin dark gray middle layer sandwiched between the black foam laying against the aluminium bulkhead plate and the thick white outer layer.
On the other side of the aluminium plate inside the Basement is yet another layer of 50mm / 2” thick EPDM foam. Can you tell I’m just a wee bit fussy about building eXtremely quite boats??!!
Just before we leave the Cabinetry team lets go back to the Cabinetry shop and meet the newest team member, Ömer. Spelled with an E and not to be confused with Ömür, we find him busy working on the first of the cabinets for the Aft Guest Cabin. This will be the bookcase above Christine’s Office desk. Just before he put on the final frame board I was able to get this close up to show how the biscuits work to align and reinforce the solid Rosewood attachments to the laminated cabinet sides. These biscuits ensure everything lines up just right and then Ömer can clamp them while the glue dries like you see in the first photo above. Similar technique being used here to attach the solid rosewood edging around the perimeter of the door for the Head. In this case you can see how the wood wedges apply added pressure to push the solid edging against the laminated foam cored door. Next day Ömer has all the clamps off Christine’s bookcase. The middle shelf goes in to finish off the bookcase cabinet. The edge of this middle shelf will be painted with white polyurethane for some contrast so it is made from Birch rather than Rosewood. Heading back to the shipyard floor beside Möbius Uğur is busy prepping the intake sea chest that will go into the Starboard side of the Engine Room. The angled bottom end of this 120mm / 5” diameter by 10mm / 3/8” wall pipe will be welded to the bottom hull plates and bring fresh sea water up to the hole you can see here. There are two of these holes where the inlet pipes he is fabricating here will take sea water over to two strainers mounted on their ends. You can see a top view of all this in the drawing on the left with the top flange of the Sea Chest on the far left and then the two strainers on the right. Once he has all the pieces of pipe tacked in place Uğur takes the assembly onboard and fits it in place in the forward Starboard corner of the Engine Room.
The flanged top will have a Lexan cover bolted to it and sits well above the waterline making it easy to see if anything gets sucked inside. There is a threaded plug and a quick connect compressed air fitting in this cover so you can use either a broom stick or compressed air to quickly flush out any such intruder.
For the technically inquisitive in the shot above that is the 25mm /1” Starboard engine bed plate sloping aft at the bottom and the Starboard water tank sitting under the two sea water inlet pipes. The large opening is one of the access ports and the round SAE5 flanges with the SS studs are where the supply/return lines attach along with Maretron and Hart system tank level gauges and temp gauges.
The bottom flanges of two Vetus strainers will be mounted on top of those vertical pipe stubs on the right above and these will then feed into a manifold that supplies fresh sea water to things like the engine heat exchangers, water maker, wet exhaust, fire hose, salt water wash down pump and other such consumers.
Two strainers are used for redundancy and each pipe has a large ball valve on it with one open at all times to supply sea water to its strainer and the other one ready to be opened in an instant if the other is clogged or needs to be cleaned out. The black knobs make it easy to remove the lids of these strainers with no tools and have clear tops for quick visual inspection on each tour of the Engine Room which we do about every 1-2 hours when underway on long passages as part of our watch routine.
Standing up on the Aft Deck looking down through the big hatch into the Engine Room lets you see how this intake Sea Chest and strainers in the lower left corner will be setup. An exiting Sea Chest will be installed in the same position over on the right side bottom corner. Both of these Sea Chest tubes are coming up through Gray Water tanks which are seldom used but can be used to hold water from the Aft Cabin shower, Workshop sink and Aft Deck Outdoor Galley sink.
You can see the ER door on the angled corner of the ER Enclosure in the top right of this photo, the two thick engine beds running from top to bottom flanked by Water Tanks on either side. In the upper center you can see the long oval foil shape of the keel running down either side of the 25mm thick keel bar that runs the entire length of the hull.
Behind Uğur, Nihat has been working on the Day Tank, laying on its side here, and has welded in the 20mm thick plate you see on the bottom. This thickness is needed for the pipe threads that will soon be drilled and tapped for a series of 3/4” SS ball valves for the fuel lines bringing fuel into this Day Tank such as the return lines from the Gardner and supply lines from the fuel pumps that transfer fuel from one of the six integral fuel tanks. There are also a series of SAE5 flanges for Maretron and Hart tank level gauges. On the bottom is a sump to contain any water or contaminants that might somehow make it all the way to the Day Tank which is at the very end of our fuel polishing and filtration system. There is also a ball valve at the top and bottom of this Day Tank with a clear length of hose between to provide visual confirmation of the fuel level in this critical supply tank.
Never a dull moment for Nihat so he also looked after cutting in the air vent penetrations in the Aft Deck that come up into the two big Vent Boxes. The one he is cutting here pulls fresh air out of the Workshop and the one aft/right of that will be for extracting air out of the Engine Room. Techie Note; the ER vent is quite a bit larger than what you can see marked out here as you want to have the exhaust venting be about 120% greater than the intake to allow for the expansion of the air as it warms up in the ER and more so to ensure that there is a slight vacuum in the ER as the air exits to be sure that any fumes and smells are pulled out. Many boats don’t have this setup and their ER’s are slightly pressurized which tends to drive fumes into other areas of the boat. and tend to have higher engine room temps which can be very problematic.
Another job on the 2DO list for Uğur and Nihat was these vertical ends of the window frames that run atop the Wing Boxes on either side of the Aft Deck area. Here you can see that they have tacked a length of vertical flat bar and capped it with a matching length of 30mm / 1 1/4” pipe. This provides both a protective caps for the end edge of the 25mm thick glass windows and the pipe adds a sturdy vertical handhold that is in addition to the horizontal one above. Cihan was too much of a moving target this week for me to catch too many pictures of him but he and his plumbers continued to be very busy throughout the boat laying down hoses and pipes for various water lines such as bilge, potable, Gray, Black and Chiller along with fuel hoses.
These are potable water lines he is securing to the white perforated AL cable/hose trays. We didn’t put some of the frame penetrations into the 3D model until after the cut files were sent off to the aluminium supplier and CNC cutter because we wanted to make some of the hose layout and routing decisions later in the build. Additional penetration holes therefore needed to be cut into the frames and stringers for these new hose and pipe runs. While having these holes already CNC cut when all the AL parts first arrived is very nice, it doesn’t take too long to cut through the 10mm / 3/8” aluminium frame plates when you have great carbide tipped hole says like this! Like little mouse trails it wasn’t hard to see where Cihan and his helper had been this week with remnants such as these as telltale evidence. And that’s the week that was August 5-9 here at Naval Yachts as XPM78-01 continues to transform from virtual 3D models and renderings into the beautiful reality of aluminium and Rosewood. Hope you enjoyed this week’s progress update and thanks so much for taking time out of your busy day to join us.
The very big Eid al-Adha holiday began here today and runs from August 11 to 14th so everyone at Naval Yachts gets a well deserved four day holiday and the yard reopens on Thursday so just a 2 day work week next. I will be using the time to keep making progress on system designs, parts and equipment order lists and designing a few things like hatch closing mechanisms, alternator and water pump belt drive systems for the Gardner and so on. I will also try to write and post some of the more technical outlines and explanations of the various major systems such as Electrical, Battery and Charging systems, engine systems such as exhaust and cooling and so on. Stay tuned for those if you are interesting in diving into those details with me.
As the title of this week’s XPM78-01 progress update suggests it was a multi faceted action fest all week. First fitting of the built in furniture in the Master Cabin picked up where we left off last week and then a flurry of new components entered the scene with the big new hatch in middle of the SuperSalon floor, hoses for fuel, water and sewage (Black & Gray Water) were mounted and the new cleats and stanchion sockets were welded into the Swim Platform.
Let’s go take a look ……………………….
Picking up where they left off last week Ömür on the left and Selim planned out the details of proceeding with the assembly and fitting of the cabinetry along the Starboard/Right side of the Master Cabin. You are standing with your back against the Forepeak WT Bulkhead looking aft to see the cabinets that went in last week from the entryway door in the far aft corner here up to the two hanging wardrobes and cabinets in the foreground. The assembly laid down on the floor is going in next and will hold the washing machine in its upper cabinet. Speaking of Ömür I would be very remiss if I didn’t mention that he and his wife added their contribution to the Naval Yachts extended family with the birth of this little cutie, Merve Eda who arrived two weeks ago. Unfortunately (I’m nuts for newborns!) I have not been able to hold her yet but I am told that Mom and Merve were home from the hospital in 2 days and are both doing very well.
Congratulations Ömür! This GA plan view will help you visualize the layout of the Master Cabin as you watch it being assembled. Sweeping stairs take you down from the upper SuperSalon into the Master Cabin with the King bed on your left and one of the hanging closets on your right as you enter. Forward of this closet along the Starboard/Right hull is a long bureau of drawers, then more hanging lockers and cabinets for the washer and dryer. Vanity sink on the far right at the very front up against the WT Bulkhead of the Forepeak and then the toilet and sink in the Head/Bathroom with the walk-in glass walled shower aft.
Back to the real Master Cabin, you can see that there is a lot going on along the Starboard hull sides and this is just some of the runs of wiring and plumbing that will go into these spaces.
When designing these boats we are always thinking ahead and working through questions like how will we service and maintain this infrastructure, how will we keep things clean, how will we access hidden areas such as the gutters in the margin plates below the cabinet bases, how do we prevent condensation, etc..
The answers to some of those questions can be seen above for example with the generous space left behind the outboard ends of these cabinets so that there is plenty of room to run all these hoses, wires and pipes. The backs of each cabinet will be removable marine plywood panels screwed in place to seal off each cabinet and still enable ready access to the entire area behind each cupboard.
Right all these components are temporarily clamped in position and all the dividers are dry fitted in place so that once every piece is perfectly aligned and in their final position, clearances are checked, doors are temporarily mounted, drawers are fitted, etc. it can all be disassembled, and carefully carried over to the finishing shop for final sanding and application of multiple coats of polyurethane varnish. Once all the systems, plumbing and wiring are installed then the finished components of this massive jig saw puzzle can be taken aboard and more permanently mounted.
When the bases are finish mounted, back panels installed and the insulated and heated floors in place, the whole area behind all these cabinets will be quite well sealed off from the interior air to prevent any circulation of this air in there. This is one of the ways we eliminate any condensation forming in cold climates. Another layer of defense is the 50mm / 2” of EPDM foam (all the black you see) which effectively keeps the interior temps very consistent and minimizes the effect of the outside air/sea temperatures as we roam the entire spectrum of climates and conditions from high latitude polar seas to tropical waters on the equator.
With the Starboard side cabinets mostly fitted they switched sides and started mounting the front wall of the Head/Bathroom on the Port side. I balanced the left door jamb on its end here to give you an idea of how the layout you see in the GA plan drawing above looks in reality. The white epoxied foundations leading aft of that door jamb will help you see where the full height etched glass shower walls will run. The two rectangles of white framing around those 4 fuel tank access hatches will provide the support for removable flooring hatch that will cover them. I received a lot of comments and questions (thank you!) about how the double duty, one door/two jambs, doors work so I’ve taken this set of photos to try to show this more clearly.
Here the door is in position in the first door jamb to close off the hanging wardrobe. I have balanced the vertical portion of the second door jamb on the right.
You can see our “Horizon Line” handhold running across the door and the surface above it will be covered in light gray leather.
This is the half way point with the door in between the two jambs right and left …. ….. and here is the door now closed into the second door jamb to close off the doorway to the stairs leading up to the SuperSalon. Check out the video at the end to see this door in action.
This inside surface of the finished door will be a full length mirror.
That’s all there is to this ingenious solution enabling one door to serve both purposes. As some of you will note, this does mean that when the door is in this position you can see into the closet but in our case with only the two of us aboard 99% of the time, this door will rarely be closed like this and will most often be closed onto the wardrobe as in the first picture.
These kinds of doors have been around for a long time as I’ve seen them in a few very old homes in Europe and a few older hotels but I have never been able to find a proper name for these or the story behind them. So if any of you happen to know more about these please share in the “Join the Discussion” box at the bottom. I was fascinated by the very first one I saw probably 40+ years ago and we also had one in our previous boat and we find them to be just brilliant in form and function. Less is more rings true here especially when it comes to multiple doors in the same area on boats and the way we have implemented them here they are another example of how we KISS or Keep it Safe and Simple.
Moving back to the Starboard side of the Guest Cabin you can see that we’ve been hosed! In a good way. Cihan was a very busy boy, along with many helpers as he continues to lay in hundreds of meters of hose. The large mostly vertical running black/red hoses are 50mm/2” fuel hose for Filling and Venting the fuel tanks. Looking up you can now see how those nifty catchment boxes work with the Fuel Fill box on the right and Vent Box on the left with just one tanks vent hose attached here. These containment boxes ensure that any overfilling or foaming when fuelling up is fully captured inside these boxes and drained back into the fuel tanks.
The black horizontal running hoses on the bottom are fuel supply and return lines from some of the fuel tanks in the Basement and the clear hoses above are for transferring potable water between the six large integral water tanks.
Cihan hamming it up a bit as Uğur shakes head and they start working on getting the fuel vent and fill hoses in place on the Port side.
They soon have this mirrored setup on the Port side by the stairs leading up to the SuperSalon.
Check out the video at the bottom of this posting to see more of Cihan’s handiwork and get a better sense of how all these pipes and hoses run throughout the boat. We tried out many different commercial hose brackets from different companies but none of them floated our boat so instead we made our own in house with a little bending jig on the hydraulic press that made short work of forming the AL flat bar into these just right shaped brackets which are riveted to the welded L-bar supports. (covered with EPDM foam in this photo) The radius of the curves was made large enough to allow a thick band of rubber to be glued on the inside and ensure that there would be no movement and now chafe between the hoses and the brackets. Checks all our boxes; Super secure, easy to access and KISS. What’s not to like??!! Evidence of Cihan’s hard work was easily seen in the Basement as well. He has also been checking throughout the installation of the hoses that the fuel system remains fully sealed which is why he has the loop here to close off this tank for pressure testing.
Looking closely in the center bottom and in the upper right of this photo you can see the white sanitation hose, still in its protective clear plastic wrap, connecting to the Gray Water tank on the right of the fuel tank.
Turning 180 degrees to look forward along the same Port side of the hull as above, with apologies for the low quality photo, we see more of Cihan’s handiwork. Two of those black EPDM insulated lines zip tied to the cable trays have PP-R (similar to PVC) pipe for the chilled water to run up to the AirCon Air Handler in the Master Cabin and the third one is the hot water loop that runs throughout the boat providing instant hot water at every tap and shower. Gray cables are 220 and 120 volt circuits, black is 12V and 24V DC. Clear hoses transfer water from the water maker to the six tanks as well as allowing us to move water from one tank to another to adjust trim of the boat.
Apologies for the poor quality photo but the white pipe running above the three black pipes carries compressed air from the compressor in the Workshop all the way up to inside the Forepeak. There are SS threaded inserts in T fittings like the one on at the right end of this white pipe which will have quick connect compressed air fittings along the way.
Compressed air is super handy for some of the tools I use, for blowing out anything that might get sucked up into the intake sea chests, cleaning out difficult to reach crevices, and lots of other super handy tasks. It is the little details that make the BIG differences right?
Oh, and did I mention that we’ll have an air horn that runs off this same compressed air for when we want to sound like the Queen Mary in the fog!
Mystery photo. Any guesses????
Drain pipe from Guest shower into the integral Gray Water tank on the other side of this WT Bulkhead in the Workshop. Uğur and Nihat are our relentless aluminium magicians and this week they turned their attention to this large 900mm/ 36” square hatch in the SuperSalon floor to access the Basement. L-bar framing went in first around the perimeter which will have a thick rubber gasket on the bottom to keep it quiet and sealed.
** Blue tape and scrap plywood is protecting the fuel manifold below from any welding spatter. The hatch was quickly fabricated from 6mm plate with L-bar frame and flat bar stringers underneath and then …… ….. checked to be a nice fit into the hatch frame.
Flat bars on the right extend up to the height of the finished floor where the SS piano hinge will be attached. Opposite side from the hinge will be a SS latch to keep this hatch tightly sealed in place and two SS gas lift cylinders will make it an easy one handed operation to lift up and hold the hatch open while taking large items to and from the Basement. With the Basement Hatch done the Dynamic Duo of Nihat and Uğur moved on to the next item on the list; installing the two cleats in the aft corners of the Swim Platform. We spent some time trying out different angles and locations and settled on this one. Does not impede people boarding from the Tender or diving off the Swim Platform, leaves a clear open space at the bottom of the stairs leading up to the Aft Deck and stays squared off to lines running ashore when anchoring stern to in narrow fjords and other situations requiring such.
Plasma gun makes quick work of punching holes in the Swim Platform deck plates …. …. and the hull underneath. (all above the WL) Cleat tubes are set down to have same 150mm /6” clearance to the deck plate as all the other cleats along the Rub Rails up on deck. While we are at it and have the equipment out let’s put in the two outer stanchion sockets and get them tacked in place. One final check that it all looks just right. Let’s tidy up these busy outer corners where the hull sides, bottom stair, stanchion sockets and Swim Platform all converge by putting in an angled plate to make a clean smooth transition between all these elements.
It was faster to make up a quick template out of pink foam board rather than fire up the 3D modeler to get this tricky transition shape just right and Uğur soon had the plate all ready for Nihat to welded everything in place. Another job checked off the list!
Sezgin will come along later with the TIG welder to lay down the top finishing weld and make these joints look even nicer. Similar to the welds you see on the horizontal cross bar and the vertical posts of the cleats. Last but not least, this week’s short time lapse video showing more details of the work completed this week. Enjoy!
Whew!! Another busy, productive and hot week with daytime highs in the30’s here this week and even higher degrees of progress aboard the good ship Möbius this week of July 29th through August 2nd, 2019.
Super happy to have you along for the ride and thanks so much for all your comments, questions and suggestions. Please keep them coming by typing in that “Join the Discussion” box below and we’ll see again next weekend with the next hot progress update from all of us here in Antalya at Naval Yachts and Team Möbius.
Cabinetry predominated the progress this week as the building of XPM78-01 aka Möbius continues “all engines ahead full”. And a very exciting new stage was added to the list of “firsts” as per this week’s title with the first of the cabinetry being moved inside Möbius and fitted into their new full time homes. Let’s go see …………
First in place is this full height wardrobe or hanging closet which is the first thing you cabinet as you see as you descend the stairs from the SuperSalon and enter our Master Cabin.
If you are new to these weekly updates and to help with orientation, here is the original rendering from many months ago of the layout of the Master Cabin. This is the view when you are standing with your back against the Port/Left side hull walls looking across the bottom of the King bed towards the entry door and wardrobe closet in the photo above.
To the left is this large bureau of drawers with the mirrored space above for our 3D sculpture of a Möbius strip and then more closets continuing to the left all the way to the forward end of the Master Cabin. This is the view when standing beside the closet as you enter the Master Cabin and look forward to the glass walled shower and head/bathroom area in the back left of this render. With the first closet clamped in place the next cabinet moved onboard is the base of the bureau of eight drawers. Thanks to having every part of the boat in the 3D model the cabinets can be made to very close to just right sizes over in the cabinetry shop which dramatically reduces the fitting needed once they are moved aboard so the process goes quite quickly.
Omur (rear) and Selim are a well coordinated team as they make the minute adjustments to getting the cabinets in just the right spot.
The white boards creating the foundation for all the furniture have been previously installed and leveled before being affixed to the aluminium tank tops that make up almost all the floors on the boat. This provides a solid level surface for all the furniture cabinets to sit upon and once they are all fully finished they will all be more permanently attached to these foundation boards as well as the surrounding aluminium frames. Where anchoring points are needed in between frames the 50mm/2” thick EPDM insulation is cut away and the AL hull plate is thoroughly cleaned prior to having an epoxy coated wood brace glued in place using industrial adhesive. The marine plywood sides of the cabinets are extended back towards the hull area inside the frames so they can slide into slots in the anchor blocks as seen here. Once the cabinets are fully leveled and fitted they will be glued and screwed to these anchor blocks and create eXtremely strong and rigid cabinetry that does not move or squeak, EVER!
One of the many benefits of building an aluminium hull with such an eXtremely rigid framework which this skeletal rendering shows and then covering it with equally eXtremely thick AL plating is that the hull does not flex or move so we take advantage of this by attaching the cabinets the way you are seeing here. The back panel above the bureau of drawers has been fitted and clamped in place along with the overhead ceiling plywood and Rosewood edge.
Omur is moving what will be the cabin’s main entryway door out of the way so that the base for the last set of full height cabinets can be moved into place and fitted. Having been previously dry assembled in the cabinetry shop as they were being made and as we’ve seen in previous updates the vertical dividers slot into place very quickly with biscuit joints top and bottom. Shelves are also attached using biscuit joints in the slots you can make out with the two slots running across the middle of this inner vertical divider. Throughout the interior all vertical corners are solid Rosewood with large 50mm/2” radius corners for both safety and great looks and you can see two examples here with the two full height radiused corner pieces that flank the bureau of drawers. Once the cabinets have been fitted and clamped in place the working hardware such as drawer slides and these gorgeous SS recessed hinges will be set in place and adjusted. The groove running horizontally here between the solid door jamb with the recess for the hinge body and the divider above it is where the custom silicone gasket will be attached to ensure there are no drafts when the doors are closed and no rattling or squeaking from any wood on wood contact.
Comfort is one of our five fundamental priorities for these boats and while these kinds of “little details” with these solid cast hinges and silicone gaskets cost both time and money to execute, noise, especially when underway is a huge factor in the overall comfort onboard so we gladly go to such lengths to create eXtremely quiet boats. When they were not onboard Möbius fitting the cabinets they’d built, Omur and Selim were working on the components to go into those cabinets such as these solid edged drawer fronts for the bureau of drawers. These will next have light gray leather panels laminated as is indicated in the rendering at the beginning. Most excitingly to me they also have these solid rosewood hand holds all ready to be attached along all the cabinets and doors with the aquamarine “horizon line” behind them as described in several previous updates. Can’t wait to show you this other unique feature once we start installing them and I can show you better how they work and what they look like. Lest you think that Uğur and Nihat were missing in action nothing could be further from the truth as they were busy working on aluminum details aboard Möbius all week as well. One job getting finished off is the closing in of the insides of the two wing boxes on either side of the aft end of the Pilot House.
The rear half will be fully welded in place and the forward one will be bolted in place. These are removable so we can attach and service the extraction fans which are in composite ducting boxes attached to their inner surfaces. There are ducting tubes connected to the Guest Cabin, Corridor walkway, shower and head and these fans can aid the airflow in these areas as needed. Don’t be confused by their temporary resting spot on and inside the Day Tank but the final aluminium detail for this week’s update is the completion of the bolt on covers for the two vent box hatches for the fuel which are located on either side of the outer surfaces of the coaming below the windows just ahead of the Wing Boxes above.
The gaskets have been glued on and these covers will be bolted in place with SS countersunk machine screws. The slots allow air to flow into the vent pipes for all the fuel tans and the Gray and Black water tanks. Sounds like another minor detail but trust me that well ventilated tanks are eXtremely important. Ask me how I know?!! And that’s the week that was July 22-26, 2019 here at Naval Yachts in Antalya Turkey. We’ll be back again next weekend with more photos and explanations of the continued progress as Möbius gets closer and closer to the water and we get more excited with each of these steps.
Thanks for joining us and please be sure to add any and all comments, ideas and questions in the “Join the Discussion” box below.
As many of you who have been following along with the design and building of our XPM78-01 eXtreme eXploration Passage Maker named Möbius, we will be powering this boat with a rather unusual but just right engine, a Gardner 6LXB. Long story behind this and if you are curious you can read THIS ARTICLE “Mr. Geeeeeeeee is in the House” from May 6th last year that will give you some of the background about this awemazing diesel engine and some of the story behind our acquiring what we affectionately call Mr. Gee for reasons that should be quite apparent as you learn more about him.
QUESTION?? Before I go any further you may have noticed that last week’s and this post I changed the photo/text layout a bit by sizing the photos larger which gives less room for the text on the right side. As always you can click on any photo to enlarge it to full size so not sure if these larger photos and less text column is an improvement or not??? Please let me know in the “Join the Discussion” box below which layout you prefer; Medium sized photos & text or Larger photos and smaller text area?
WARNING!! Knowing my love of all things mechanical and especially Mr. Gee, I suspect my Gearhead tendencies will make this post rather long on greasy engine parts and short on shiny new aluminium and beautiful Rosewood cabinetry. However there WILL BE some coverage of all the other facets of progress this week involving aluminium, wiring, venting and the Rosewood cabinetry, so either get yourself a comfy seat and a favorite beverage or else hit the page down key to scroll through the engine mechanics a bit more rapidly to the sections that follow that catch your attention. Or for the really fast synopsis check out the video at the very bottom.
Now back to our regular programming…………………………
If you’ve read the previous article I linked to above you will know that we were able to enlist the expert help of Michael at Gardner Marine Diesel in Canterbury England who spent several months searching the Gardner world for an unrestored original marine version 6LXB and finally found one in a tugboat in the Thames River that was going to be upgraded to a Gardner 8LXB and so we were able to buy the 6LXB when it came out and was shipped over to Canterbury. Christine and I were house/pet sitting a fabulous villa for some very dear friends of ours in Albufeira Portugal for about six months so we had Mr. Gee sent by truck to Portugal so I could begin the rebuilding process to restore Mr. Gee to better than new condition. Once we had settled into our new home base here in Antalya Turkey and began the building of Möbius with Naval Yachts Mr. Gee when for his next set of truck travels and was delivered to us here and has been patiently awaiting some loving attention ever since.
A very long winded, as usual, lead in to the fact that this past week I was finally able to devote a bunch of time to the restoration of Mr. Gee and so that and the progress on many other parts of the boat will be the focus this week. So enough telling and let’s get to showing you the week that was July 8 to 12, 2019.
First, just to put things in some context here is a brief photo synopsis, with some repeating of last year’s posting, of the journey Mr. Gee has been on from my first finding him in England back in 2017 and the journey he has been on leading up to me beginning to work on him again this week here in Antalya.
Meeting Mr. Gee for the first time on July 14th 2017 at Gardner Marine Diesel in Canterbury with CEO Michael Harrison.
Eye of the beholder I’m sure but as my fellow gearheads might be able to understand it was love at first sight! Completely original and untouched since he was first installed in the tug in the Thames in1975. Next stop Albufeira Portugal. Mr. Gee being unloaded along with a pallet full of brand new Gardner parts to replace every part other than the aluminium and cast iron castings and crankshaft. Proud parents with their new little baby weighing in at a mere 1100 kg as many parts have been removed for shipping and are on the other pallet. Gardner logo proudly cast into these valve covers on the two independent heads. Captain Christine, resplendent in her official Gardner hat (thanks Michael!) unpacking and carefully recording inventory of all the new Gardner replacement parts. Everything but the original engine castings and crankshaft will be replaced with new parts from Gardner Marine. Now begins the first of what will be many disassembly’s of the entire engine so that everything can be cleaned, restored/replaced, polished and painted. Quick trip to the local industrial hardware store to get this hydraulic lift, jacks and support stands to provide the power to lift these VERY heavy parts such as the cast iron cylinder block. Pistons and connecting rods all removed and stacked up waiting to to be pressure washed. For a sense of size and scale here is one of the connecting rods. With a total displacement of 10.45 liters each of the six cylinders is just under two liters which is is the same size or larger as many of the cars we drive daily. Down to the bare cast aluminium crankcase and the beauty of that solid cast aluminium starts to shine through. Out with the 44 year old cylinder dry liners and in with brand new ones and top all surface ground back to like new. Cast iron cylinder heads also sporting their freshly ground surfaces along with new valves, valve guides, seats and springs. Time is up as Christine and I need to start our several month trek in our trusty Galloper, seen in the background here (thanks John & Michelle!) over to Rhodes to pick up their Lagoon 500 sailing cat and deliver take it over to Antalya for them, or so we thought at the time. Mr. Gee and Mr. Crane had become intimate friends so they insisted on traveling together and ….. were soon all swaddled in shrink wrap to await their next adventure being trucked to Antalya Turkey. Several months later Mr. Gee and all his parts arrives into the Antalya Free Zone. And is carefully put to bed inside Naval Yachts to await the next stage of the restoration process. Fast forwarding to this past week with Mr. Gee up in his 2nd floor workshop courtesy of Naval Yachts the next disassembly begins to pick up where we left off in Portugal with the cleaning and restoring.
Second tear down goes much faster and I soon have him stripped down into his basic parts.
With all the internal parts removed it is time to put all the castings back together so the entire exterior can be sealed up and ready to head off to be sandblasted back to bare cast iron and aluminium. One slight problem some of you may have caught in the text above; Mr. Gee is up on the 2nd floor and the long extension crane can’t get into the shipyard building right now with so many boats in the way so how to get him back down to ground level? No problem! Yiğit on the left and Uğur lend their keen minds and strength and we take out the window frame, raise the forklift up outside and lift Mr. Gee onto the pallet. Uğur shows off his many talents with masterful forklifting and we soon have Mr. Gee back on the ground, heads set in place and aluminium plates bolted over all the exterior holes to keep the sand out. One of the great benefits of having so many shipbuilders in the Free Zone is that they can all share some of the larger bits of equipment like boat movers and in our case sand blasters. Turns out that Damen, the huge German shipbuilding company with about 5 different buildings here in the Free Zone, were blasting a large steel hull and agreed to let us drop off Mr. Gee for a good blasting with Garnet based sand to really get rid of every bit of his 44 years of accumulating dirt, grease and oil.
Doors closed and a few hours later we went back to find a very naked Mr. Gee sheepishly awaiting our return. WOW!! Talk about clean! And now back to Naval Yachts for the next round of the process. Naval has their own cabinet style sand blaster which I will soon be using to clean the hundreds of smaller parts but we took advantage of the big sand blasting rig to clean up things like the engine mounts you see on the pallet as well a the cast iron exhaust manifold standing up in the center here and the cast bronze engine oil cooler to the right. Such a prime example of a bygone era of engines and engineering, this solid bronze engine oil cooler is probably my most favorite part on our Gardner 6LXB. I’ll show and tell you more as I take this all apart to clean and restore the interior cooler in the coming weeks. And speaking of prime examples, check out the inside of this elbow on the exhaust manifold. THIS is what true thermal efficiency looks like in a diesel engine! This is the amount of carbon “buildup” after FOURTY FOUR YEARS of solid work almost every day in the tug boat this came out of. Nothing new for a Gardner and there is almost no equal when it comes to such overall thermal efficiency and a big part of why Mr. Gee is the just right engine for our Möbius. Sandblasting is awesome when it comes to getting metal parts absolutely clean but they are so clean that they begin to rust or oxidize in the outside air almost immediately so you need to get them painted FAST! Yiğit was able to source some super tough high heat silicone based primer that is good for up to 600C / 1122F While I waited for the primer to arrive I used compressed air to get rid of any lingering sand, filled up my spray gun and spent the next few hours giving all the parts two good coats of this special primer. Mr. Gee and I are both feeling MUCH better now and looking forward to the next stage of the restoration so stay tuned for much more. Meanwhile back inside Naval Yachts Uğur, Nihat and Sezgin were busy finishing up the welding of the Bow Thruster tube and the Sea Chest tubes in the Forepeak. The remainder of the weld around the concave fillet is next up to be ground fair and smooth. I thought this shot will help show just how lean and mean the underwater bow section of the hull is as it is only about 400mm / 16” wide at the bottom of the bow thruster tube which is already about 2.5 m / 8.2 ft. aft of the front of the bow stem bar. Should slice through the water like a knife! More finish welding getting all these fuel tank vent elbows and the vent pipes for the Black and Gray water tanks fully welded in place. And right behind the Fuel Vent Box the Fill Box has its prototype lid test fit with its rubber gasket to check that it all fits and is watertight. Down on the shop floor one of two plates that will be bolted to the ceiling to create the large air plenum for all the fresh air flowing into the SuperSalon, is having the 120mm / 5” duct pipes prepped for welding. One of these plates goes above the Main Helm station and the other goes over the center of the SuperSalon and each of the 5 ducts will have an adjustable diffuser set inside to spread out and control the flow of fresh ocean air.
Similar vent ducts are also being welded through Aft Deck which will be covered by the large Vent Boxes overtop to divert more fresh air down into the Guest Cabin and its shower. These duct pipes extend down inside and the ceiling panels will fit around each one and then have the white diffuser snapped in place to complete the finished ceiling vent. The nautical miles of hoses and cables continues to flow into the Basement as ….. ….. Hilmi and his new intern put in more cable trays …. …. and then start to fill them with the beginning of the long runs of cables, 24 volt DC in this case ….. …… and fuel hoses in this case. The penetrations through the SuperSalon floor above the Basement are also starting to fill up with the cables that lead up to the SuperSalon and Helm stations as well as going up to the SkyBridge and its Helm station. Winding over to the Cabinetry shop which many of you say is your favorite, we find Omur on the left and Selim ripping some Rosewood strips for the solid edging that goes around each door and drawer……. …… which end up looking like this prior to heading over to the big veneer press to have the Rosewood surfaces applied. First solid edged doors are test fit into their respective locations on this set of wardrobes in the Master Cabin to ensure that all their edges are precisely parallel and even. A day later with the veneer all applied and edges rounded another test fit to check that the grain patterns also line up as per Omur’s expert eye. Ignoring the blue tape holding them in place you can start to get a sense of how fabulous these cabinets will look once the boys in the finishing shop have applied all the clear satin polyurethane to really make that Rosewood grain pop. As per this construction drawing, the top doors above the aquamarine coloured handgrip/horizon line will be covered with a light gray leather to complete the look. While I have the shop drawings out some of you have been asking for more details on how the handrail and Horizon Line detail will work and this section drawing of the row of wardrobes with the inset detail in the lower right should clarify. The Hand Hold/Horizon Line are part of the cabinetry and then the upper and lower doors close shut onto it. This is what the partially finished hand hold / Horizon Line assembly looks like. Without the doors in place, here is what the Rosewood hand hold works like this. This plan view of the whole Master Cabin should help you visualise how all the various cabinets are laid out. Our King bed is at the bottom with the entrance door to the right. Full height wardrobe to the far right of that door and then moving forward there is the Bureau of Drawers in red with the 3D Möbius strip sculpture set back from the long row of wardrobes we’ve been seeing built above. The top right two spaces in blue are where a washer and dryer will go and then the vanity sink in the center up against the WT bulkhead with the Forepeak on the other side. Toilet/Head in the upper left corner with the adjoining glass walled shower. Not shown are the 3 stairs at the top left corner of the bed which takes you up to the raised floor alongside the whole left side of the bed and the Port hull wall.
Shifting over to the large bureau of drawers for the Master Cabin this closeup shows what I refer to as the “quilted” style with these radiused edges wherever two Rosewood components meet. These are small details which require more time and effort but they all combine to really add that touch of craftsmanship to the whole room and are easily worth the investment and help make this our Goldilocks “just right, just for us” boat.
I didn’t manage to juggle the video cam with all the work on Mr. Gee too well but here is a video synopsis of most of the other areas where great progress was made this week. Hope you enjoy.
Thanks as always for choosing to join us and spend your valuable time following along with the progress on motor vessel Möbius the very first XPM78-01 to be built here at Naval Yachts.
We’d be most appreciative of any and all comments, ideas and suggestions you have so please click on the “Join the Discussion” box below and type them in. I WILL answer all of them though it may take me a few days to get to them all.