The focus this week was on building the aluminium Console for the Upper Helm Station in the SkyBridge (the GO part of this week’s title), getting Mr. Gee his fuel supply, continuing to check off more electrical and interior jobs and prepare our anchor chain for anchoring (the Stop part of this week’s title).
We were delighted to welcome back more members of Team Möbius as they return from the other boats they’ve been working on so let’s jump right into this week’s Show & Tell so you can see it all for yourself.
SkyBridge Helm Station
Here is the design we came up with for the aluminium console that will hold all our navigation equipment for the Upper Helm Station in the SkyBridge. Click to enlarge this (or any image) to see some of the items that will be installed in this console and I’ll put a list of all of these below.
As shown in this layout drawing, the equipment that will be mounted in this console include:
2 Side by Side 24″ LiteMax NavPixel Daylight Readable Touch Monitors
Furuno 711C Autopilot Control Head
Vetus Bow Thruster Joystick Model BPAJ
Maxwell VWC 4000 Windlass Up/Down Control
Kobelt Engine Throttle and CPP Pitch Controls
Kobelt Pitch Gauge
Standard Horizon GX6000 Fixed-Mount VHF Radio
Kobelt Control Switches & Remote Walkabout plug-in socket
SH SCU-30 Wireless Access Point
Exterior Lights switch panel
Engine Stop/Start buttons
Although the SkyBridge area is quite well protected by the solid roof above created by the aluminium frame for the 8 320W solar panels mounted on top, and the removable plexiglass windows which wrap 360 degrees around the whole SkyBridge, it will still be exposed to wind and rain at times so we needed to build a waterproof console to protect all these critical and eXpen$ive electronics. We had been working on the design of this console for a long time and were very pleased to be able to enlist the help of Burak who had been our 3D modeler when we first started working with Naval 3 years ago, to work out the details and finalise this design. One additional design element we needed to accomplish was that this whole console needed to be removable for two reasons. First being that it needs to be removed when we convert the boat to “hunkered down/Canal mode” and lower the articulated roof. And secondly Christine and I want to try out having this Upper Helm Station in different locations in the SkyBridge as we use the boat for the first year or so. We think that its current location at the Aft end of the SkyBridge will work out best but we won’t know for sure till we can live with it in different scenarios and different positions.
Burak sent over all the 2D construction drawings last week and so Uğur jumped right in on Monday morning and spent most of this past week taking this console from start to finish by Friday. Let’s follow along as he works. It would have taken another week or more to send out all the AL plate to be CNC cut and I think Uğur enjoyed the chance to go back to some “old school” ways so he quickly laid out all the parts directly on the AL plate and cut out the pieces with the in-house bandsaw and a cutting disk on his angle grinder. As we have tried to do throughout the design and build of XPM78-01 Möbius, we KISS’ed (Keep It Simple & Safe) the design of this console so there are only 8 pieces in total and they are all made out of 5mm / 3/16” flat AL plate which are easily tacked in place. To provide ready access for installing and maintaining all the electrical connections and components inside this console we made the whole back side a removable plate that will be bolted in place with a watertight gasket. With a quick check that all the dimensions and angles were all correct, Uğur got to work doing all the finish welding.
BTW, for those who might wonder why all the photos of welding have these lines in them it is due to the MIG welders being the newer Pulse type and the camera freeze-frames these pulses. With the welds cleaned up a bit Uğur laid out the various cut-outs for each item to be installed on the dashboard and then cut these out with a hole saw or cutting wheel. We are still waiting for a few switches to arrive but we have all the primary components so Uğur and I did a quick check to make sure they all fit properly before continuing. Next it was time to finalise the location of the console on top of the foundation built into the SkyBridge (and for Cihan our Master Plumber to get in this quick cameo!) The two cushions on the Port/Left side allow someone to comfortably join the person on watch as well as a great spot to lie down for a nap up here. After trying a few different spots we settled on this positioning with the same amount of overhang around the three sides. This is our Llebroc Helm Chair which will soon …….. reside here, in the center of the space behind the dashboard.
This penetration on the inside provides a watertight pass through for all the cables. Once all the cables have been installed and all systems checked that they are fully functional, this and all other penetrations throughout the boat are filled with certified “goo” to create a fully watertight seal. Here is how the Upper Helm Station it looks from the back side. Holding the camera at about eye height here to check the sight lines which are great as you can easily see the whole forward end of the bow anchor area. Whenever we prefer to have an even better close up view of around the boat, we have one of these Kobelt 7176 “Walk-About” remote controllers at both Helms.
With 10m / 33ft of cable, I’m not willing to trust wireless for this critical control, we can stand almost anywhere on the boat from the Swim Platform to the Bow, either side deck and from anywhere in either the Main or SkyBridge Helm areas and have all the controls literally at our fingertips when docking or take this remote controller to wherever we are sitting.
The two side levers control Throttle and Pitch and up on top are controls for Rudder, Bow Thruster, CPP Clutch and Horn. Can’t wait to try all these out on our upcoming sea trials once we launch.
And Yes, Launch Date is still “Thursday”, just don’t ask which one!
We finally have Cihan back full time again (we hope!) and he was his usual busy productive self all over Möbius. Cihan and I started by working on the two heat exchangers ….. …….. that needed to be mounted in the very aft end of the Engine Room. We built in this removable section of the flooring to provide full access to this important area where the prop shaft enters the boat. The composite grid flooring lifts out and then this aluminium floor plate can be unbolted and removed as well. Access is particularly important whenever I need to service the “dripless” Tides Marine SureSeal Drip Free Self-Aligning Shaft Seal that keeps all the water out of the joint where the prop shaft exits the log tube. I will cover more details when we are installing this SureSeal but here is a quick overview of how it works. Today though we wanted to access the very aft ends of the two Engine Beds on either side where we wanted to mount these two Bowman heat exchangers. The red one on the far Port/Left side is for cooling the hydraulic oil in the Nogva CPP Gearbox and the Silver one on the far Stbd/Right side is for cooling the Gardner’s water/antifreeze engine coolant. Both of these heat exchangers have cool seawater being pumped through their outer shells while the oil is pumped through a round “stack” of CuNi (Copper/Nickle) tubes that you can see here in this cutaway illustration. Fun Fact: Bowman is another one of the world leading industrial companies we have found here in Turkey and so it was fun to find that our Nogva Norwegian CPP system came with that Red Bowman Heat Exchanger.
My apologies for getting too busy to get too many photos of this installation of these two heat exchangers but the basic flow of the seawater is that it first enters the Left end of the Silver Heat Exchanger at the top of this photo, exits out the rear and then flows through the Gray (protective wrap) hose on the far Right here where it will enter the aft end of the Red Heat Exchanger at the bottom. Inside the Engine Room, the seawater exits the front end of the Red Bowman Heat Exchanger through another rubber hose that goes up to the Halyard SS mixing elbow on the Gardner’s wet exhaust system and then exits the boat through the large Exit Sea Chest in the ER. Much more to come on all that once we start installing the exhaust system in the next few weeks. Another new plumbing addition that Cihan installed this past week is the small little circulation pump with the White faceplate you can see at the bottom middle of this photo of the underside of the Stbd/Right side Workbench in the Workshop. These Jabsco/Xylem 24V “vario” pumps are very cool and very eXpen$ive but boy do they work well. These are a relatively new pump generation that are super quite with minimal energy consumption, shaftless spherical motor and permanent magnet technology. On Möbius we are using this D5 Vario 38/700B pump to keep hot water circulating through our DHW (Domestic Hot Water) loop that ensures that there is always hot water immediately available to every hot water tap and shower on the boat. No more wasting time and water while you wait for hot water to come out of the sink faucet or shower nozzle!
Speaking of hot water, the Captain aka Christine, is eXtremely eXcited about Cihan installing two of these SS towel warmers; one in each cabin’s Head/Bathroom!
Christine has been wanting to have one of these for years and after a very long and winding road to find these Goldilocks just right versions, she will finally have one in our Master Cabin as will all our guests in their Bathroom. Yet another example of the Turkish manufacturers making eXtremely high quality products, Christine fell in lust for these “Laris” model SS towel warmers from Hamman Radiator. The towel warmers attach to the walls with these very clever SS tubes which Cihan first attaches to the walls using an expanding bolt on the inside of each tube.
And then there are four round SS pegs on the back of the towel warmers which slide into these tubes and are locked in place with the little set screw you can see on the bottom here.
The two SS square fittings the bottom are the water valves to control the flow of hot water through the towel warmer.
Here is what the finished mounting looks like.
Many won’t understand, but to my eye, all of this hardware and the towel racks themselves are just beautiful works of art and engineering that are part of our “boat jewelry” collection on Möbius.
Looking around our Master Head/Shower/Bathroom do your sharp eyes might spot a few other new additions?
One job Serkan just completed is the mounting of those two SS latches now installed on those bottom two cabinet doors underneath where the sink will mount. And if you look very closely you will see that the White Corian countertop has arrived. There will be a clear glass partition that extends up that slot between the shower seat and the ceiling and will be sealed to that vertical surface at the end of this countertop. And what is this new addition that just showed up this week beside the VacuFlush toilet? Aha! That’s the wireless remote control panel for the BioBidet BB-1000 Supreme bidet seat. It clips into a holder mounted on the cabinet so the curious can remove it and discover all the MANY functions available. The same BioBidet is installed in the Guest Cabin as well BTW.
Surely you didn’t think I put the eXplorer in XPM for no reason did you?
More examples of how XPM78-01 Möbius is a true world eXplore can be seen in another new addition this week as Hilmi starts installing all our Vimar “Arké Metal” switches and plug ins. We have designed Möbius to be a true “World Boat” and so she has both 120V 60Hz and 230V 50Hz AC plugs like these throughout the boat. We also have wired CAT7 ethernet plugs spread throughout the boat for maximum internet speeds. This one is tucked away below the “floating” shelf on Christine’s side of our King size bed. And these are what the matching Vimar light switches look like. Of course these will all look MUCH better once we remove all the protective plastic coverings and do a good cleanup prior to launch, but until then we are very glad to have all the interior surfaces covered up while construction continues. And here is Hilmi installing a set of four of those Vimar switches for the LED lights around the stairwell leading down into the Master Cabin. Serkan has also been busy in the Master cabin adding finishing touches such as these solid Ro$ewood handholds on the “Swiss” (as in Swiss Army Knife) door that is the door for both the entrance into the Master Cabin and the full length hanging locker as it is here. He needed to radius both ends of these so that they cleared the door jambs when closed on the Entryway. The upper panel will soon be covered with the same Green/Gray leather you see throughout the Master Cabin walls.
Nihat also had a very productive week as he took on the eXtremely big job of finishing all the exterior aluminium surfaces. We’ve settled on the “brushed” look that these 3M abrasive discs create when used with a random orbital sander such as this pneumatic one in the photo here.
Let us know what do you think of this look but we are very pleased with it.
Feeding Mr. Gee!
I managed to make more time for Mr. Gee again this week and focused on installing his “feeding” system to deliver the Goldilocks just right amount of scrupulously clean diesel fuel.
This is one of his six fuel injectors that have been refurbished to factory new condition by Michael and his crew at Gardner Marine Diesel at the Gardner “factory” in Kent England. Injectors just don’t get much better or simpler than this. NO electronics just a simple supply connection under the Red seal on the Right and a matching return connection on the Left. Each injector slides into the tubular hole you can see underneath the tip of the injector here. Then one of these lever arms is tightened down using the castellated nut just to the Left of the Red cap here. This lever presses the angled end of the injector body into its matching seat inside the tubular hole in the cylinder head and forms a perfect seal to keep all those literally eXplosive forces inside the cylinder where they belong and where they then supply all the mighty “draft horsepower” and torque that Mr. Gee delivers to our propeller. Now each of those injectors need an equally robust set of piping to deliver the diesel fuel to/from them so my next job was to clean up all these steel fuel lines and give them a couple of coats of shiny black epoxy.
Can’t have any bare steel on Mr. Gee that would just rust now can we?! Here is what those shiny Black steel fuel lines look like when they are connected to the bottom outlets on the Fuel Injection Pump and then go up to the injectors in the cylinder heads through the AL valve covers I have set in place here.
Again my apologies for being too busy installing all these fuel components to take more photos but I will take more this coming week and put them into next week’s Progress Update for you.
For now I hope this quick shot of where I left of yesterday (Sat. Oct. 10th) will do.
Yachts Play Games Bula Bula Right?!
Christine and I spent Saturday morning doing a job that believe it or not, we have long been looking forward to; painting the length marking strips on our 13mm / 1/2” galvanized HT anchor chain.
The joy in this job is that it reminds us that in the not too distant future (we hope!) we will be using these marks to tell us how much anchor chain we have let out in the latest anchorage we have just arrived at.
We started by dragging all 300 meters / 328 feet of chain off the factory pallet onto the shop floor and arranging it in 10 meter long loops with paper underneath both ends where we would be spray painting the chain. There are a LOT of different ways to mark an anchor chain and even more opinions about which is best but we have both anchored thousands of time in our marine lives and find that painting different colours onto the chain and then adding some matching coloured nylon zip ties is the Goldilocks just right method for us. We paint a different colour combination each 10 meters / 33’ and to help us remember the distance of each colour we came up with the acronym YPGBR based on the colours of paint we have used this time. As you might figure out from this photo, YPGBR stands for Yellow-Pink-Green-Blue-Red which is the order of the colours we painted onto the chain every 10 meters.
These are the odd numbered 10 meter marks starting with Yellow at the first 10m mark at the top here, then:
Pink @ 30m,
Green @ 50m,
Blue @ 70m
Red @ 90m At the other end of the loops we use a combination of the colours to mark the even starting lengths of;
Yellow/Pink @ 20 meters
Pink/Green @ 40m
Green/Blue @ 60m
Blue/Red @ 80m
Nope! Easy for us to remember when the YPGBR acronym stands for is:
Right?!! For those who might wonder, Bula is the Fijian greeting, always said with great Gusto, which we learned so well from all our years cruising in Fiji
Once the paint dried we flaked the chain back onto the pallet and it is now ready to be pulled aboard into its Chain Bin inside the Forepeak but that will have to wait for next week’s Progress Update here on Möbius.World.
Thanks as always for joining us and be sure to add your thoughts and ideas in the “Join the Discussion” box below.
This week’s Progress Update will be short and sweet as we are still working very shorthanded on XPM78-01 Möbius and it has been another very full weekend of boat related work for Christine and me so it is already late Sunday here as I sit down to write up this week’s Progress Update for you. However, progress is being made and there are interesting new developments to show you so let’s jump right in for this week’s Show & Tell aboard the Good Ship Möbius.
Serkan was onboard for two days this week as he continues to work on the last of the hardware related work in the Master Cabin. On Tuesday he was installing the last of these beautiful SS latches on the doors and drawers on the front Starboard/Right side wall of the Master Cabin. He is down to the last latch on the bottom drawer below the vanity sink that you can see in the bottom Left here. A bit different perspective on Thursday, looking straight down the centerline towards the bow of the boat you can see that the bottom drawer has now been installed along with the two matching latches on the White bottom cupboard doors inside the Head/Bathroom on the far Left.
And Serkan has almost all the Green/Gray leather panels installed now, just the small strips around the Vanity cabinet at the far end. The door of that Vanity as well as the main Head door will soon have mirrors mounted on them to finish this area off. Upstairs in the SuperSalon an exciting new development is now visible. The window frames are now all filed with their plywood templates which will be sent out to the glass company next week so they can cut and prep all the 25mm/1” thick laminated window glass as well as the other glass for the flush Deck Hatches. And the “eyebrow” around the upper SkyBridge.
Still very much a “work in progress” but the whole SuperSalon is beginning to come into view now.
It will be a VERY big day when we finally get all the glass installed onboard and make Möbius fully weathertight for the first time.
Our faithful Dynamic Duo of Uğur and Nihat had another full and productive week. If you were with us last week you’ll remember they were busy getting the ceiling over the Outside Galley on the Aft Deck all fully insulated wtih 50mm EPDM foam and the attachment points for the White AlucoBond laminated sheets that will form the ceiling itself. As with the other AlucoBond panels you’ve seen them mounting in the Engine Room and Workshop, they use these very nice covered screws to attach the AlucoBond to the aluminium L-bar supports. If you look closely at the screw in the upper Left here (click to enlarge any photo) you can just make out the brass threaded washer around the head of the countersunk screw and then the chrome dome cover thread onto that to completely hide the underlying screw head. Here is what the ceiling looks like viewed from down inside the SuperSalon looking up and out the Entryway WT Door onto the Aft Deck Galley.
For those wondering, the White, Black and Red lettering is just a protective film on all AlucoBond panels which will be removed just before we launch to reveal the White anodized aluminium outer surface of all these panels. And here is what it looks like from the other end out on the Aft Deck.
The Black wiring hanging down is for the six LED lights when we are cooking in this Outdoor Galley or dimmed down for safe lighting when entering or leaving the boat. This is the Port/Left Vent Box which served double duty as one of our Outdoor Galley countertops with this SS sink in it.
The rectangular openings are filled with the Mist Eliminator grills and damper system for the Entry Air going down to the bottom of the Engine Room. And this is the matching STBD/Right side Vent Box with the two rectangular openings for the extraction air from the Engine Room and Workshop.
The raised surface on the Left will be the main countertop in this Galley and the lower countertop will soon house the 220V electric Grill/BBQ.
All the countertops will be Turquoise Turkish marble to match that in the inside Galley.
For the observant ones who might wonder, the two small outlets on the Aft facing bottom of this Vent Box on the far Right are for the quick connect water fittings for our Deck Wash hoses; one for Fresh Water, one for Salt. However the most exciting new milestone Nihat and Uğur hit his past week was that they started on the final cleanup of all the bare exterior aluminium surfaces. Nihat spent most of the rest of the week working on the AL surfaces surrounding the SkyBridge.
This is a two part process, first grinding all the welds to be either flush or nicely radiused corners such as you can see Nihat has done here on the frame for the SkyBridge Console and the surrounding interior walls. Then he moved on to all the AL surfaces and welds on the surfaces outside of the SkyBridge itself. Such as the tops of these “horns” on either side of the Front hinged Solar Panel bank and the outer walkway that runs down the sides of the SkyBridge. Uğur took on the daunting task of grinding down all the welds on the outside surfaces of all the Hull plates. There are three longitudinal runs of welds down each side where the different thicknesses of hull plates butt together. The top one he is working on here is the only “hard chine” or corner on the hull which is a bit trickier as the weld needs to be ground down flush to each plate and then have a nice radius for the turn of the corner. It is difficult to capture in photos, especially at this early stage but this will give you an idea.
The surface on the far Right here is part of our experimenting with different kinds of final swirl patterns for the final finish to see which one we like the best. This shot will help you see how the process of finishing this corner seam goes. The corner on the far Left is close to what the finished chine or corner will look like and as you move to the Right towards Uğur you can see the progression “backwards” through the process with the raw untouched weld on the far Right. This longer view will help you understand the “daunting” part of Ugur’s job! 24 meters / 78 feet down each side suddenly becomes a VERY real and very big number when you are taking it on one centimeter or inch at a time and then three of those lengths (one for each weld seam, on each side. I’ll let you do the math! The maximum sheet size for aluminium plates is 6m/19ft so there is also a vertical seam where each end of the plates butt together that also needs to be ground flush. And up at the Bow there are a lot of transitions where the different hull plate thicknesses, 10, 12, 15, 20 and 25mm thick all come together where they meet up wtih the 25mm thick Keel Bar and that nice round transition up at the top where it wraps around our big solid AL “nose” cone for the snubber line when at anchor. By quitting time on Friday though Uğur and Nihat has already done their first passes of their welds on the Stbd/Right side so that was a LOT of progress in just a few days. Lots more to come next week so stay tuned as I show you the continued evolution of finishing the hull.
The newest member of our growing family of Victron equipment finally arrived and got installed this week. It is the newest Victron Blue box that you can see in the bottom Right corner of this AL panel in the Forward Port corner of the Basement.
If you click and zoom in on this or the photo below, you can see that this tiny Cerbo GX box provides us with communication ports for USB, Wi-Fi, Bluetooth and a MicroSD slot as well as the Victron VE.Can nd VE.bus connections.
We have had Victron equipment on our previous boats for many years with great success but one area that has been lacking is their integration in communicating with each other and the whole GX line is helping to resolve that. The Cerbo GX is also the newest bit of kit from Victron and makes a huge leap forward in getting all our Victron equipment onto our N2K network as well as bringing all our Victron into a much more integrated system. Just around that front Port corner is our “Solar City” wall where all 14 of our Victron SmartSolar 100/20 MPPT controllers which connect to each of our 14 320Wp Light Tech solar panels. The Gray box is the junction box for all the wiring and the 14 circuit breakers for the DC outputs of each MPPT controller.
Diagonally opposite on the Stbd Aft corner, we managed to steal our Plumbing Wizard Cihan back for one day and he finished installing the last 2 Whale Gray Water Tank pumps. This pump extracts Gray water out of the integral AL tank below and pushes it out the Sea Chest that you can just barely see on the far Left here.
Given that we are rarely in marinas and on anchor, the vast majority of the time our Gray Water (sinks & showers) goes directly to an exiting Sea Chest but when that’s not allowed, the Grey Water is stored in one of our three Gray Water tanks and hence the need for this Whale pump to empty those tanks when we are out at sea.
The big Clear/White tank on the Right is our Potable Water tank which ensures that we always have at least 150 litres of pure water to use even if we should somehow loose all access to the 7100L/1875USG of fresh water in our six integral AL tanks in the bottom of the hull.
Some of that fresh water goes into this HazMat Locker on the Port side of the Swim Platform for our Aft Shower. As you can see here we have hidden the shower mixing valve and head inside this locker to keep it out of the way and protected from daily UV and salt water. Cihan has mounted a holder for the shower spray head inside here as well so it is easy to just open the locker and grab the shower head to rinse off after a snorkel exploration or for a nightly shower. There will be another showerhead mount up on the Aft railing so you can have a hands free shower as well for shampooing your hair or whatever. Inside on the front Stbd/Right side of the Workshop by the Day Tank, Cihan was also able to install these two Black hockey puck shaped Maretron FFM100 Fuel Flow Meters. The upper Left Fuel Flow Meter is on the Fuel Supply line going into the dual FleetGuard 2-stage fuel filters and the one on the lower Right.is on the Return Fuel line from Mr. Gee our Gardner 6LXB engine. Having these high precision flow meters allows us to know the exact amount of fuel being consumed at any time and helps us run Mr. Gee at his maximum efficiency at all times. And if you were to bend down and take a peek underneath the Day Tank you would see this latest addition Cihan has made out the bottom of the Sump on the Day Tank. The Black threaded nipple you see here is where the WIF or Water In Fuel sensor will be installed. Being heavier than Diesel fuel, water always sinks to the bottom so if we ever get any water in our fuel is will quickly find its way down to the bottom most point and send us a WIF signal and sound an alarm.
If you go back and look two photos above at the FleetGuard Fuel Filters you will see that each of the Fs19596 Fuel Filter/Separators has their own WIF sensor in the bottom so we are sure to know if water ever shows up in the fuel at any time and we can promptly get rid of it before it has any chance to get near Mr. Gee.
Speaking of Mr. Gee, I was able to spend more time working on him this past week focusing on timing and plumbing so let’s head over to the Engine Room to take a look.
This was an exciting new milestone for Mr. Gee and me as I finally got to mount this Fuel Injection Pump and Cam Box assembly taking up most of the Port/Left side of Mr. Gee. If you look at the far front end you can see the PTO (Power Take Off) shaft coming out of Mr. Gee which turns the fuel injection camshaft that in turn created the high pressure that goes up to each injector sprayer at just the right time. At the aft or flywheel end of the Gardner it is Grand Central Station for all these Copper & Brass lubrication oil pipework’s. They all come together here where the cast iron Oil Filter acts as the traffic cop for all the oil coming and going to the rest of the engine. Many hours of “pipe wrangling” later, this is how the pipework’s look when all connected to the Oil Filter on the top Right here and then going heading on to their connections on the other end to the crankcase, oil cooler which has its own dedicated oil pump which is the Burgundy painted unit extending out of the AL Cam Box in the rear Left here. I won’t bore you with all the details, but Gardner engines have multiple “timing” settings that are critical to get absolutely spot on for the engine to run properly. The timing of when each intake and exhaust valve needs to open and close is one example that I tackled this week. The requirement is that the Intake Valve opens at 16.25 degrees Before Top Dead Center and the Exhaust closes at 11.75 degrees Aft TDC. But how do you measure and set to such accuracy? The method I came up with was to put a piece of masking tape on the outer circumference of the flywheel covering the distance between the two precise lines punched on at the Gardner Factory to mark TDC and 25.8 degrees BTDC which is for timing the fuel injectors. Then I peeled off the masking tape and laid it out on a flat AL surface where I could accurately measure the distance between “zero” at TDC and the 25.8 degree line with my digital Vernier calipers which gave me the numbers I needed to figure out how many mm one degree of rotation is. Pretty simple math that even I could figure out. It was 127.7mm from the TDC line to 25.8 degrees so 127.8 / 25.8 = 4.872mm = 1 degree. Easy to then mark off the distances for the 16.25 degree and 11.75 degree marks. Now all I had to do was put put the masking tape strip back on with the TDC mark on the tape matched up with the TDC mark on the flywheel and then mark the flywheel at the 16.25 BTDC and 11.75 ATDC lines and then put a center punch mark at each one and scribe a line through them. Lining these marks up with the reference line you can see scribed into the top and bottom of this opening in the flywheel housing and I can turn the flywheel to align these marks and precisely adjust the valve timing at each point.
That will be where I start tomorrow (Monday) morning so I’ll let you know how that works out in next week’s Progress Update.
So this is the parting shot of Mr. Gee when I left him last and where I will start tomorrow morning. And my first order of business will be to find the slob that dribbled that bit of Wellseal gasket sealer on the top of the cam box! Oh wait, never mind, I just caught my reflection in the monitor and I found him! Thanks for joining me here on this week’s Show & Tell for the week of September 27 to October 3rd, 2020. Really appreciate you taking the time to follow along and I sure hope you will add your comments, questions and concerns in the “Join the Discussion” box below.
Starting with the biggest news first; Christine and I took a much needed “mental health day” by renting a car and driving up the coast for an overnight getaway in a lovely little area we’ve been to before that is only an hour’s drive from our apartment in Antalya. We’ve been working non-stop seven days a week for the past six months and thought it would be smart to take a brief break from boat building.
We are very fortunate that the Antalya Free Zone and our apartment are at the very far West end of the city of Antalya that stretches over 30km along the long crescent shaped coastline of the Gulf of Antalya you see here. The mountains rise up around us less than 1km from the beach and we only drive about 2km SW to put us on a fabulous coastal road along the tree lined rocky coast.
Christine found a fabulous little cabin for our getaway in a little village which in the 60’s and 70’s was the center of an area filed with “hippies” from around the world who built a lot of treehouses which have now evolved into little resorts with 2-10 small cabins on the property. So I left the shipyard very early Friday afternoon at 15:30 and we packed up the pups and some snacks and were on the coastal road by four. We checked into our little cabin and then spent a few hours walking through the small village along the river front which filled with lots of arts and crafts shops, cafes and restaurants which led us down to the pebbly beach where our boat dogs Ruby & Barney enjoyed being back to salt water beaches after almost three years of being dirt dwellers with us.
As you can see in the photo above, the beaches are as usual jam packed with other people.
The little “resort” we were at was run by a lovely Turkish family who cooked up a fabulous dinner that evening in an open air patio where we were almost the only guests to enjoy the owners excellent selection of jazz music during our long and leisurely dinner. Our host family again delighted us with a classic Turkish breakfast the next morning and we spent the rest of the day driving along the coast and up into the mountains to explore everything from Lycian tombs (click photo on left to enlarge) to mountaintop Roman ruins complete with amphitheatre and acropolis. We treated ourselves to dinner at our local marina which is only a few blocks from our apartment and the whole experience felt like much more than just an overnight getaway that really helped recharge our batteries for the final push to finish Möbius and Launch!
Back at Naval Yachts, it was another week of disappointedly limited progress on XPM78-01 Möbius herself as their other boat projects seem to take precedence. The bright spot though was that our dynamic duo of Uğur and Nihat make a LOT of progress on the Davit Arch as they finished welding the Davit Arch onto the Aft Deck and it is now ready for rigging.
In the Master Cabin, Serkan continued his single handed work installing the last of our favorite SS latches and he and Sinan completed installing the leather covered panels on the upper cabinet doors and the Bureau of Drawers. Out on the Aft Deck, with Uğur welding the Davit bases to the deck, Nihat turned his attention to installing the EPDM foam insulation in the overhead roof and the big ER Deck Hatch.
So grab a comfy chair and a favorite beverage and join me for this week’s Show & Tell Progress Update aboard XPM78-01 Möbius.
Might as well start with the star of this week’s Show & Tell; the Davit Arch!
Retrieving any dinghy in rough weather can often be eXtremely dangerous so we have been working since the early design stages with Dennis over three years ago now, to design a Davit system that is as safe and as fast as possible.
Christine and I hope that our fellow cruisers who have launched and retrieved their share of dinghy’s and tenders will weigh in with your thoughts on this system by adding your comments and questions in the “Join the Discussion” box at the end of the blog.
First a couple of quick renders to show how we’ve designed this somewhat unique launch/retrieval system for the jet drive Tender to Möbius which you’ve seen being built in the previous weeks.
We had a very good hinged Davit system I had designed for the aft end of our previous sailboat that worked extremely well to launch and retrieve our 4m/13’ aluminium bottom RIB in under a minute so we took all the lessons learned there and used them to help guide us in the much more greater challenge of having a similarly safe and fast Davit system for our now 5m / 16/5’ 1100Kg/2400lb aluminium inboard diesel jet drive Tender. Right now Möbius is sitting too close to the boat next to it inside the shipyard to be able to do a dry run lifting the Tender On/Off the boat so we will have to wait until we launch to find out in real world terms how well this design is going to work. However, between the two of us, Christine and I have cruised for many decades now and have launched and retrieved dinghy’s thousands of times spanning the full spectrum of different sizes and types of dinghy’s and tenders using an equally wide range of davits and we think this Davit Arch system will prove to be the safest and easiest to use Davit system we have ever used. Stay tuned for that real world testing report in the next few months.
As you can see we have used the same type of “ladder” construction for the Davit Arch as on the Main Arch as this style has proven to be a Goldilocks combination of strength to weight and we also really like the overall visual esthetic of this matching pair of arches and how well it fits in wtih the overall eXpedition look of XPM78-01 Möbius. I updated the design just before we ordered the aluminium to make the arch a three piece assembly that bolts together very simply using two doubler plates (light blue in the model) at the transition between the vertical legs and the horizontal beam. This allows us to dismantle the arch and take it down completely either in what we refer to as “Hunkered Down” mode in preparation for an impending cyclone (ask us how we know!) or for “Canal Mode” when we want to eXplore inland canal systems found throughout the world that have bridges with height restrictions lower than our air draft with the Main Arch and Skybridge roof and Davit Arch up. Raising/lowering the Tender will be a very simple two stage operation and I will explain this all in much more detail wtih photos in a future Weekly Update when we start doing the two sets of rigging.
1. One set of rigging will move the angle of the Davit Arch itself from the near vertical Cyan coloured position you see in the first render above that puts the Tender fully up on deck and then lets the Davit Arch move sideways towards the Port/Left side until it reaches the Purple coloured position where the Tender is now clear of the Deck.
This rigging will be an all Dyneema setup starting with two attachment points at the Forward/Aft end of the overhead beam connecting to a a single line extending over and down through a turning block straight across the Deck on the Starboard/Right side Rub Rail and then lead to the big EST 65 Lewmar electric winch in the middle of the Aft Deck.
2. The second rigging will be a double set of vertical hanging lines to raise/lower the Tender in the Davit. When the Tender is up on Deck these will raise/lower the Tender from its chocks and when over the side it will raise/lower the Tender from the water. This will also use Dyneema line attached to a bridal clipped to four attachment points inside the hull of the Tender leading up to a block and tackle handing down from the Front and Aft ends of the overhead beam and leading back down to two EST40 Lewmar manual winches mounted inside of each vertical Arch leg.
With all that in mind let’s go see how Uğur & Nihat, aided by their student intern Omer, made this all come together this past week. I will use the same technique as many seemed to like in covering the build of the Tender; a rapid fire set of photos with just a little bit or text along the way. Here goes………………….
If you would like to review the building of the various components of the Davit Arch system you can look through the past 3 weeks of posts which covered their construction. This week Uğur began by machining the two large cylindrical Hinges; one at the base of each vertical leg of the Arch.
He had welded the two Base Plates out of 20mm/ 3/4” AL plate a few weeks ago so now he was ready to machine the 100mm / 4” OD aluminium cylinders that fit between the two triangular sides on the Base Plates and the two SS Hinge Pins that slide through to create the Hinge. KISS, Keep It Simple & Safe design for the whole hinge with these two SS Hinge Pins that have an end cap bolted on to keep them in place and snug up against the sides of those triangular support arms on the Hinge Plates. While the Hinge Pins were being machined, Uğur and Nihat mounted the AL cylinders into the holes in the 25mm / 1” thick plates at the base of each vertical leg. Some scrap pieces of AL were tacked on to hold the cylinder in perfect alignment and then welded them fully in place with multiple passes on each side. All three parts now complete and ready to be bolted together to form the completed Davit Arch. Aligning the holes in the two doubler plates. And securing them with six 16mm / 5/8” bolts. Torquing down all the bolts, Hinge Base Plates ready to be attached with their SS Hinge Pins. Like this. et Voila! The Davit Arch is upright for the first time and ready to be moved up onto the Aft Deck of Möbius.
But how do we do that when the forklift can’t lift the Arch up high enough??? Simple! Uğur quickly fabricates this Forklift Crane eXtension (patent pending) using some scrap lengths of 8” square steel tubing with a chain hoist and block hung from the top and the base jammed into one of the forks of the forklift.
Oh, and a couple of strong men to help steady the Arch in place. Up Up Up goes the Arch …….. ……… as Uğur inches the forklift into the very tight space between Möbius and Twinity, the big composite catamaran hiding behind the scaffolding and plastic on the Right here. The Forklift was till a wee bit too short for the Aft Hinge Base Plate to clear the deck but some pry bars and muscle helped to raise it the last few inches and the Davit Arch was no up and ready to be positioned precisely on the Aft Deck. The laser level and a long tape measure allowed us to get each Hinged Base Plate in the same position that we had worked out on the 3D model. And each plate was tacked in place so we could do some real world measurement and testing to make sure the somewhat complex geometry all worked out as in the 3D model for getting the Tender to clear the outer edge of the Port/Left Rub Rail and then get it fully on Deck to meet the requirement that no part of the Tender extends out past the vertical line of the outer Rub Rail. A worms eye view from the Swim Platform looking up the Aft Vertical leg of the Davit Arch and a good vantage point to see how the Davit Arch hinges on the Base. Our digital level was a big help in checking the angle of the vertical legs when they are in the fully upright position where the Tender will be Lowered/Raised on the Aft Deck.
We designed this to be just a bit less than vertical so there was always a bit of weight on the rigging when the Tender was hanging from the Davit Arch so the Arch would start to move as you loosened the line on the winch and belayed the line to move the Tender sideways and over the Port side where it can be lowered into the water. Now I needed to see exactly where the Centerline of the keel of the Tender would be when lowered onto the Aft Deck so I scrounged around the yard and found two of these weights. Not sure what they are or used to be but they worked just perfect to be Plumb Bobs that I could string from the top of both ends of the Davit Arch and mark the spot on the deck with my felt pen when the Plumb Bob string was exactly vertical. With the forward and aft Plumb Bob points marked, a laser level and a 6 meter length of aluminium L-Bar provided enabled me to lay out the full centerline on the Aft Deck and then use this as our reference line to measure the position of the Davit Arch and Tender as they moved from fully onboard to fully off the Port side. It took me several hours of laying out all the positions of the Tender and its clearances over the side as well as clearing the Port Vent Box you see off to the Left of the front Hinge Base.
We tried out about three different positions and tacked the bases in each one as you can see evidenced here with some of the previous tacks that were ground off so we could reposition and get that Goldilocks just right spot. You can see some of the different locations and colours I marked out on the deck until I though it was just right. and gave Uğur the go ahead to weld them fully in place. Here is what the Forward Leg of the Davit Arch looks like now fully welded in place. And here is the Aft leg of the Arch now fully welded in place just inside the stairwell down to the Swim Platform. As mentioned up in the beginning, the Tender is lifted Up/Down in the Davit Arch via two of these EST40 Lewmar winches. This is the Aft winch. And this is the Front Winch. These EST40 winches have two speeds and are self tailing which should make lifting the Tender up off its deck chocks and out of the water very easy to do. Once the Tender has been lifted up high enough for its bottom to clear the side deck, moving the Tender sideways onto the Aft Deck is even easier using this much larger and electric EST65 Lewmar winch. You can now visualize how this single line from the winch goes up to the two bridle lines that go over to the front and aft ends of the Davit Arch. And you can now see one of several uses for those two 50mm/ 2” thick aluminium Fairleads extending up out of the Starboard side Rub Rail. Once we have the Tender strapped down into its chocks on the Aft Deck all the weight comes off the Davit Arch and I wanted to make sure that it was well secured when we were on passages. Uğur came up with this simple design of two plates welded to the sides of the roof that sandwich the front vertical leg and …… …. is then captured when the Arch is fully raised and rests against the forward side of the Roof overtop of the Aft Deck Galley. We will make up a pin to slide through the two sandwich plates so that the Arch could not come loose and I may make this with an eccentric cam so I can lock the Arch tube tight against the rubber bumper that will be glued to the Roof edge and make for a nice tight holder that won’t rattle or move. It is difficult to photograph the overall Davit Arch so I climbed up on the racks that separate the far bay in the shipyard to get this photo looking down at the Aft Deck of Möbius and Twinity off to its side.
Hope this helps to also give you a better sense of size and scale to the Aft Deck, Swim Platform, etc..
AFT DECK INSULATION:
In between building the Davit Arch, Nihat got busy putting in the 50mm / 2” thick EPDM foam insulation on the underside of the AL roof that extends out overtop of the two Vent Boxes.
These two Vent Boxes are primarily there to bring fresh air in and stale air out of the Engine Room and Workshop but we put them to double use as our Aft Outdoor Galley by making their tops out of the same Turkish Turquoise marble as in the main Galley and installing a nice SS sink on one side and our electric BBQ Grill on the other. Up to now, the underside of this overhanging roof looked like this and so Nihat got busy filling in all those channels with 50mm thick EPDM foam insulation. Like this. Prior to putting in the EPDM foam, he welded in all the short lengths of aluminium L-bar you see here …. that will be used to attach the White Alucobond ceiling panels which they started cutting out down on the shop floor beneath. This is a view of that ceiling looking up from inside the SuperSalon through the main entrance door. And while he was in an insulation mood, Nihat removed the large AL deck hatch overtop of the Engine Room and glued in all the 50mm thick EPDM onto its underside. As with the rest of the walls and ceiling in the ER, this EPDM will next be surfaced with White Alucobond screwed to those AL L-Bars he has welded into the frame of the Hatch.
Last but not least for this week let’s go check out what’s been happening with the interior of Möbius.
The Captain is VERY happy to see these two SS towel warming racks finally show up at our apartment after months of searching to find them, putting through the order, getting them through Turkish Customs and finally getting them delivered. They are both the same and one goes in our Master Head/Bathroom and one in the Guest Cabin Head. Beautifully made, this is one of the brushed 316 SS valves that connects the towel rack to the SS Hot Water fittings mounted in the walls. Can’t wait to show you what these look like when they’ve been installed so do stay tuned for that in a future episode here. Serkan our Hardware guru, continued with his installation of those lovely SS latches I’ve been extolling ad nauseum the past few months. He is now down to the last of these as he installs the final four on these lower cabinet doors on the Starboard side of the Master Cabin. With so many to install and the need for each latch barrel to be in just the right spot, he has build this little jig to make it easier to drill the pilot hole for each latch. Sinan had previously covered the panels for all the upper cupboard doors and the Bureau of Drawers with their beautiful Green/Blue leather and Serkan now has them all mounted and installed all their SS latches. Looking forward along that same side with the Bed platform on the Bottom Left and the Shower/Bathroom Upper Left, you can see how the Master Cabin is starting to come together. Bathroom door now hung and most of the Bathroom cabinets in place waiting for their Corian countertops and then the iridescent blue glass sink can be installed. Same style glass Blue sink is in place in the Vanity at the very front end of our Master Cabin. The upper part of the door will soon have the same Green/Blue leather panel installed along with the door handle that will look like this. Which is actually the handle installed on the “Swiss” double acting door for the Entrance to the Master Cabin and the tall Wardrobe on the Left. I detest drafts, squeaks and rattles so all the interior doors have these silicone based seals inserted into thin slots cut into the corner of each door jamb. As is so often the case it is the small details like this that make the difference between good and eXceptional and I smile every time I feel the soft squish as I close one of these doors and feel them seal tight as the door latches closed.
In the Absolutely Must Have category as well as the “Don’t ask me how long it took to get these here” category, it put an even bigger smile on our faces when these Crosby anchor shackles finally arrived. Our anchor chain is 13mm / 1/2” but we were able to upsize the critical link between the chain and the anchor to this 16mm / 5/8” shackle. One of the key bits of kit that truly help us Sleep Well At Night or SWAN as we often call it. And THAT my family, friends and followers is a wrap for the week that was September 21 to 26, 2020. Hope you enjoyed this week’s Progress Update and PLEASE let me know your thoughts, concerns and questions in the “Join the Discussion” box below.
Thanks for joining and I hope to see you here again next week.
Another slow week aboard Möbius unfortunately with the combination of lack of staff to another boat ‘Caledonia” that launched on Friday and an unexpected 4 day week due to two workers testing positive to Corona 19. Those two men who had both been working together on Caledonia have been quarantined but and the rest of that team were all tested so we are hoping that we can get back to work tomorrow, Monday here.
However, Uğur and Nihat made great progress on the Tender and I got in some solid days working on Mr. Gee so I’ve got lots to show you and let’s jump right in to this week’s Show & Tell.
Serkan our Hardware specialist, has continued with the installation of all the many latches and gas lifts on the cabinetry doors and drawers in all three cabins. Below is a short little video that will do the best job of showing you how these work.
Now that we get to try these out we really like how our design has all worked out for these Galley Garages. As you can see in the video above, even when you have messy fingers while cooking, a simple flick of your finger allows the door to fully open and move out of the way so you can grab whatever you need inside. These gas filled lift cylinders snap into SS mounting balls which you screw to the inside of the cabinet and the door so while Serkan needed to spend a bit of time figuring out the exact placement of these mounts with the first door, it goes very quickly after that.
I thought the instructions on the plastic bags the cylinders come in would do the best to show you how this works.
The Silver coloured one I’m holding here is a Lift cylinder so it compresses when you close it and is what is used on the Galley Garage doors. The White one on the counter is a “drop” cylinder so it works in the opposite direction to slowly lower our fold down doors where you flip the latch open and then the gas cylinder slowly telescopes out to smoothly lower the door to its fully folded down position rather than free falling open.
Exciting for Christine and I to see that we are now at the stage where our OGM Navigation Lights are getting mounted.
Uğur and I came up with this simple design for the mounting bases that go on each side of the coaming around the SkyBridge for our Red/Green side nav lights. For those not familiar with COLREGS, the standards governing navigation lights for ships of all sizes, this graphic shows the nav light requirements for a power vessel a over 20m/65ft length. For the Port/Starboard Red/Green lights must have a Horizontal View Angle of 112.5 degrees and >70 degrees Vertical so they must be mounted at an angle of 33.75° from the centerline of the vessel. I’ve been using these OGM nav lights for 15 years with great success so sticking with what I know for Möbius. The body is CNC milled out of a solid block of aluminium and then the 2 nautical mile LED sets behind a glass lens and the whole light assembly is “potted” in epoxy so there is nothing to come loose or leak. KISS at its best!
Up on top of the Main Arch we have these 2 OGM lights, a Single White Steaming Light: Visible over a 225 degrees arc forward with the all around 360 degree White Anchor Light mounted above.
Yet to be installed at the end of the Aft Deck is one more OGM that is a Separate White stern light covering 135 degrees Aft. Just up front and off to the Port side of Red/Port light is this GPS head which is dedicated to providing the satellite based GPS data to …………. …………. our em-trak Class A AIS transceiver that is mounted overtop of the Main Helm. We like to have a lot of redundancy for our GPS data so this GPS head is one of five that we have all together onboard Möbius.
Given our speed and size we decided to upgrade the AIS Class B we have had on our previous boats to this Class A unit and the table below explains why.
With Class A we get bumped up to high priority over other boats with Class B, increased power and range broadcasting at 12.5W vs 2W
Dynamic information is transmitted every 2 to 10 seconds while underway and every 3 minutes while at anchor vs every 30-180 seconds on Class B.
Not cheap, but one of our five principles for Möbius is Safety, so when it comes to Safety at Sea we don’t compromise. Courtesy of Digital Yachts site here is a nice graphic (click to enlarge) and overview of AIS (Automatic Identification System).
AIS is the mariner’s most significant development in navigation safety since the introduction of radar. The system was originally developed as a collision avoidance tool to enable commercial vessels to ‘see’ each other more clearly in all conditions and improve the helmsman’s information about his surrounding environment. AIS does this by continuously transmitting a vessels identity, position, speed and course along with other relevant information to all other AIS equipped vessels within range. Combined with a shore station, this system also offers port authorities and maritime safety bodies the ability to manage maritime traffic and reduce the hazards of marine navigation. Due to the great safety benefits offered by AIS, this technology was made compulsory throughout the world in 2002 for all passenger ferries and vessels over 300 gross tonnes.
Nihat is one of our most efficient and hard working members of Team Möbius so while he was waiting for Uğur to lay down more of the finish welds on the Tender, he would move over a few feet to work on cleaning up the welds on the three part Davit Arch.
Here Nihat is working on the long horizontal cross member of the Davit Arch and the thick plate you can see on the far Left in that photo has a matching plate on top of the vertical legs of the Arch. My thinking with this design is that it makes it much easier for us to dismantle the whole Davit and store it on deck when we want to transform Möbius into her “hunkered down” configuration for canals or in hurricane/cyclone conditions when we would also lower the SkyBridge roof.
Prepping for Propulsion:
I was able to spend much of this four day week inside the Engine Room on Möbius getting Mr. Gee ready to have his best buddy our Nogva CPP Servo Gearbox mated to him. This is looking forward at Mr. Gee’s massive 100+Kg flywheel which now has the Nogva aluminium SAE14 frame bolted on.
Each of those rounded “teeth” around the inner circumference will fit precisely with the matching grooves on the hard rubber Flexible Coupling which is bolted to the input shaft of the Nogva Gearbox. Like this. Makes for an eXtremely solid yet eXtremely quiet flexible coupling of the 180 Draft Horsepower coming out of Mr. Gee to the Nogva and on to the CPP propeller. Turning around to get this shot of the SS Prop Shaft protruding out of the AL Prop Log Tube I needed to get the Prop Shaft perfectly centered in the Log Tube so I made up this little jig to do so. Just a short bit of AL tubing machined so it snugly fits into the space between the Prop Shaft and the Log Tube like this. The two halves of the Red Nogva flange you see in these photos will be bolted to the end of the Prop Shaft on the bottom Left here and then this flange must be very precisely aligned with the matching flange on the output of the CPP Gearbox. I’ll show you all that in a week or so.
Mr. Gee Gets Dressed:
Remember that big 24V starter motor you saw being rebuilt and painted the past few weeks? Well here is what it looks like when slid into place on Mr. Gee’s Aft Starboard side. More Gardner ingenuity to make removing the starter so easily, it slides straight aft like an artillery shell into a cannon and you can rotate it to any position and then cinch it up tight with the silver band clamp you see here. I’ve put the terminals on the bottom so the big cables will be well protected by the starter above and have a straight run out below. It also felt great to finally get to fit this Bronze Beauty aka the Engine Oil Cooler, put in place just above the starter and below the Exhaust & Intake manifolds.
Seawater will be pumped into the 90 degree Bronze/Copper pipe at the far end and then out the curved copper pipe in the bottom center here. Up at the Front Stbd/Right side of Mr. Gee is this centrifugal coolant/water pump that is driven by a gear off the timing chain inside the cast AL Crankcase on the Left. The Coolant/water is pumped out through the AL manifold on the Left here and into the two Burgundy Cast Iron Cylinder Blocks. Surrounded my more Beauty, this time in the form of one of our two “tiny” Red 250Amp @24V Electrodyne alternators. Time for me to start fitting these monsters to equally robust mounts I still need to finalise. For this one I’m going to reuse the same method the original Gardner engines did by using strap mounts same as you just saw on the Starter above, to solidly attach the alternator to those three curved you can see are cast into the Crankcase. Then two straps wrap up and around the alternator body and are cinched down with a threaded stud.
As you can see, I also need to finish assembling the big Red Electrodyne Junction Box for all those White wires coming out of the alternator body on the Right. The Junction Box is just sitting loose right now as I measure everything up prior to fitting this in place onto Mr. Gee’s side.
Flip my Tender!
Uğur picked up where we left off last week with some final checks on the critical positioning of the cast aluminium mounting frame which Castoldi supplies with their 244 Direct Drive Jet. That cast AL Mounting Frame is shown in Blue in this render and the Grey plate on the right is a partial view of the 20mm / 3/4” thick AL plate Transom with what I’m calling the “Mickey Mouse cut-out” to create the whole opening in the boat where the Castoldi will bolt to. This is what the whole Castoldi 224DD looks like with the Jet nozzle on the Left and if you look back and forth between this and the render above you will be able to see the mounting holes around the whole jet drive casting and how they will fit into the opening above. Cast aluminum is often a different mixture of the alloys than aluminium plate and can be challenging to weld so we wanted to sure there would be no problems welding this cast AL Frame into the Tender’s Hull plates. Those three cross members spanning the Frame above are temporary so Uğur did a test weld on this one and a small scrap of 6mm AL plate and then we all took turns trying to break the weld with long levers. Didn’t budge or crack so we are good to go. Always a bit of hesitation when it comes to cutting holes in the bottom of our perfectly good boat and especially one THIS BIG! But it was soon done and we’re ready to start installing the Frame.
But first, we decided to flip the hull 180 degrees to make working on the bottom so much easier so strap yourself in and I’ll do another rapid fire set of photos that many of you have said you’ve been enjoying to walk you through the whole flip. Handy having a Forklift is rather handy! One last check fit of the cast Frame into the opening in the Hull.
You can also see the outline of the Mickey Mouse cut out etched ty the waterjet cutter into the Transom. We debated whether to have this Mickey Mouse cut out by the CNC waterjet when all the plates were being cut but we decided it would be better to leave it until now when we could double and triple check its position and get the jet drive in the exact right location.
Aluminium is such a great material to work with and even at 20mm/ 3/4” thick, Uğur was able to make quick work of cutting out the majority with a jig saw while I kept the blade cooled with cutting oil spray. Ta-DA!
I think even Walt would be proud don’t you? Frame tacked in place now ensuring that one of the most critical aspects is that the front edge of the Frame on the far Left here and thus the body of the Castoldi that fits into the Flange, are flush with the bottom plate of the Tender. Seen from above it looks like this. Frame now fully welded into the Hull and Transom. Captain Christine arrives just in time for the start of the Big Flip! Airborne now. 180 degrees, Half way there….. 140 and counting ………. 180! We’re flipped. Nihat wastes no time jumping in with his angle grinder to start cutting the deep V grooves so Uğur can get full penetration with his MIG gun as he follows soon behind with the first full length welds. Like this. MIG welder up and Uğur gets down to business! Time for me to get busy as well as I need to remove a few bits and pieces from the fully assembled Castoldi still sitting inside its factory wooden box.
This is the forward leading edge of the Jet Drive where the water initially enters through the grates underneath the far Left of the cast AL body. I need to remove this electric driven hydraulic pump which powers the Jet’s Steering nozzle and Jet Drive Bucket.
Input Flange where the jack shaft from the 110 HP Yanmar HTE will connect via a flexible coupling and jack shaft. Propulsion direction Forward/Reverse/Sideways is accomplished by moving the big Bucket overtop of the jet’s nozzle which is done by moving the rod in this hydraulic cylinder on the Stbd/Right side. That cylinder above connects to the Bucket like this. I’m very impressed by the design and build of this Castoldi Jet Drive and it only takes me minutes to remove all these parts and have the Jet Drive stripped down and ready to be installed in the hull. A well tuned MIG welder sounds like a very big buzzing honeybee and all the while I’ve been prepping the Castoldi, Uğur has had his MIG gun buzzing merrily away …. as he lays down all those first long lengths of full welds and then goes over them all again with the second final bead. Et Voila!
The bottom of the hull and the Castoldi Frame are all welded in place. We double check that the Frame is still properly aligned and that the heat from all the welding has not warped anything but all is well.
Time to cut out those temporary supports in the Cast AL Frame. And Mickey is now ready to receive his Italian Bride! Who has now also been flipped over 180 and ready to be lifted out of her box and into the Tender. Forklift makes it all very easy and able to lower it slowly in place. And unfortunately I have to leave you and the Castoldi hanging at this point as I was too busy helping Nihat get the Castoldi lowered in place and do all the measuring and checking of the fit to be able to take any more photos. Sorry!!
But I’ll be back to pick up with all this next week so I’ll leave you with this mini cliff hanger for now and hope that you’ll forgive me and join me again next week.
Thanks for joining the adventure and be sure to leave all your questions and comments in the “Join the Discussion” box below.
Merhaba as we say here in Turkey, to all our faithful blog readers. Just for a change of pace, this is Christine here and I wanted to let you know that we have heard all your many requests asking for a video tour showing the current stage of construction of our new boat and home Möbius. So it is with great pleasure that we are finally able to honour your requests.
It had been a year since the last full video tour, and lots has changed for sure. Wayne just loves to talk and write – at great length – about his beloved Möbius, so one day he just took the camera and spent the next several hours walking through the boat and talking about it. That was a few weeks ago now on July 15, 2020
Wayne is far too busy working on Möbius right now to do the editing, so I took it upon myself to learn a new program (DaVinci Resolve, for those who are interested) and start my new career as the Möbius World video editor. I apologize for taking so long to get this done, but it had been a long time since I had done much video editing and the program is complex.
Also, there was A LOT of footage to take on for my first project; thanks Wayne! So I decided to divide it in half and create a two part series for you, Part I of the Exterior of Möbius and Part II of the Interior, both of which you will find below.
First, a few notes about what I’ve done to these videos so you know how best to navigate your way through these quite long videos to get at just what you want.
For those who want to skip through and just look at the portions of the video that interest you, I’ve divided the video into chapters which you can access two ways.
When viewing these videos on YouTube if you look in the text area below the video window, you will find a list of the Chapters in this video. Click on any of the topics in that list to jump directly to that Chapter in the video.
When watching the video if you hover your cursor over the bottom of the video window the timeline will appear at the bottom of each video and you will see some dashes or marks along that timeline bar where each Chapter starts/ends. If you hover your cursor over any bar a pop up text will tell you the name of that Chapter and if you click it will jump directly to that point in the video.
Here is are the lists of the Chapters in each video to give you an idea of what you will find when you watch the videos by clicking on the two video windows below.
Our first full 5 day work week for Team Möbius in a long time plus another full day for Hilmi and I yesterday (Saturday) so much more to share with you for this week’s Progress Update report. Several new jobs began this week, new aluminium arrived, Mr. Gee got some much needed TLC and then we did have the “runaway” incident as per this week’s title.
AND, compliments of Captain Christine there is a bonus surprise video embedded along the way below!
So grab your favorite beverage and strap yourself into your comfy chair and let’s jump right into this week’s Show & Tell here at Naval Yachts.
Miss Möbius Tries to Runaway from Home!
Our little girl “Miss Möbius” has been growing up quickly over the past two years and based on her behavior this week I’m thinking that “boat years” must be like “dog years” as she seems to have become a teenager. How else to explain that earlier this week she tried to make a run for the sea and run away from home?!?
Or maybe, like her owners, she just got frustrated by the ever changing Launch Date?
Or maybe her big Nose Cone sniffed the smell of the sea blowing through the shipyard with the big winds we had on Monday and decided to make a run for it?
Whatever the reason she somehow had managed to conspire with her new best friend, 56 Wheeled Wanda, the second biggest boat mover in the Free Zone, to come pick her up and they were headed out the door when Captain Christine caught wind of their plan and tried to block them from leaving. Alas, the barn doors were wide open and there was no stopping them and they were off and running for the sea.
OK, OK, just kidding.
The real reason is that a big new refit and stretch job on a 36 meter/120 ft yacht is arriving at Naval on Tuesday and they need the entire length of the bay Möbius has been in so they needed to move us out and over to the opposite side of the shipyard. We’ve been storing all the major equipment yet to be installed down on the floor underneath Möbius so that all had to be moved first. Everyone pitched in and the forklift helped out and it was soon all clear below. Uğur and Nihat put in four longer supports that went all the way up to the rub rails so they could cut off the shorter ones to give room for ………….. ……….. 52 Wheeled Wanda to slid her two rails full of hydraulic jack stands all the way under the anxiously awaiting Miss Möbius. Each dual set of wheels have one set of hydraulic cylinders that can turn them to a very steep angle that allows them to move the boat sideways. Every other set of axels have their own hydraulic drive motors built into their hub to power the wheels forward or back. The two side rails are locked together using the big cross tie rails you can see here. The whole boat mover is completely self contained and this single diesel motor powers a very large hydraulic pump pushing high pressure hydraulic fluid down all those steel lines you see extending down the upper area of the side rails. And all this is run by a radio remote control unit that you can see hanging from the neck of Wanda’s operator standing on the left of Nihat here.
And just like that, the whole bay is now empty and ready to be VERY fully filled up with the new 36 meter job to take its place this coming week. We couldn’t stop Miss Möbius entirely but we were able to thwart her escape and redirect her back into the shipyard two bays over and what should be her new home until it really is time to have Wanda help us take the fully finished Möbius to the sea!
Now the moving process is reversed and the steel stands are moved back in place under the length of the central Keel Bar to support Miss Möbius so that Wanda can set her down and leave. The side stands are welded back in place and the concrete floor is drilled for long steel pins and lag bolts to keep her upright.
And we can say “Bye Bye, See you soon” to Wanda until we need her again on Launch Day. Möbius’ new “bay mate” is “Twinity”, a 20 meter/ 65 ft catamaran who’s height and width make Möbius look positively diminutive but she’s the Just Right size for us. For some perspective and sense of scale I shot this photo looking the length of the shipyard from one floor up in my Workshop. Möbius used to be in the empty bay on the very far Right here and now sits in the background by the big bay doors. the other ship tented in plastic in the foreground is “Caledonia” an all steel sailboat that should have her launch date next month sometime. Up on Möbius for the first time in her new home, we hope that she is a bit more content with her big nose cone as close to the doors as possible so she can keep enjoying those fresh breezes blowing in from the launch harbour a few block away. And hopefully no more than a few months away!!!!
But Wait!!!! There’s more!!!!
We have heard all your many requests to have more video content of this whole process and so Captain Christine has been spending a lot of time in the past month getting up to speed on some new video editing software she really likes and she will be using this to create some more video for us to post here with all the “spare time” she has between the 7 day work weeks we are both logging to try to get Möbius finished and launched.
We both did our best to shoot some video of Moving Möbius and so here is a time lapse video Christine just put together. Hope you enjoy it.
New aluminium arrivals mean new jobs so can you guess what this pile of pipe is for?
Two new jobs actually, first as you’re about to see is building the new “mini arch” or Antennae Arch that sets atop of the Main Arch to provide a “roll bar” kind of protection around the 2m/6.5’ open array Furuno FAR1523 Radar antennae and also provide all the real estate for the myriad of different antennae, GPS, weather station, satellite compass, search light, etc.. With all the various roles I’ve taken on for the build in the past few months, time is in limited supply so I just created this quick hand sketch of the design I came up with for the new Antennae Arch and the critical placement of each bit of kit that mounts on it.
I’m not sure how legible this will be (click to enlarge) but here is the list of each numbered item on the Antennae Arch.
Designing this Antennae Arch and the placement of each item is perhaps one of the best examples of how much compromise is a big part of design in that almost every one of these items has its own quite strict set of requirements for placement relative to how high it is, how much above/below its neighbors, how close to centerline, etc. Of course most of them would like to be an “only child” and be the highest of them all with no one else nearby so you quickly realise that you just have to prioritise each item’s requirements and then do a triage type process of putting each item in the best position possible.
Christine and I spent two days putting our heads together to come up with this eventual layout and I’m sure it could be improved upon even further but we think this is at least good enough for now and we will see how it all works in the real world once we launch and start using all this equipment and we can make changes from there. We’ve had a list for what we call “Rev 2” and “Rev 3” with the changes or improvements we would like to make in the coming years so we’ll just add these to those lists.
Once they had Möbius moved Nihat and Uğur dove right into that pile of pipes and elbows and started to build the Antennae Arch. The elbows needed to be altered a bit as the angle of the corner of the arch is greater than 90 degrees so that’s what Nihat is up to here. The ends of each pipe and elbow are bevelled to create a deep V for maximum penetration of the weld and then tacked in place. The first of the dual mini arches that will be built to match the Main Arch they will be welded to the top of. Like this. We are using this ladder type construction in several places on Möbius; the Main Arch as you have seen for a long time and now this mini-arch that goes on top and soon you will see this same construction on the second new job that some of this new aluminium pipe is for, but I’ll keep that for next week.
We went back and forth on whether to just have the interconnecting ladder pipes all the way across the top or to put in a solid plate and decided that the plate was best as it creates a well protected wire chase to run all the many wires and co-ax cables from all the antennae and other equipment. Uğur has framed in the bottom for two plates that will be bolted and sealed in place to help protect the wiring further. And here is the completed Antennae Arch. Yusuf on the far Left, Nihat and Uğur and I then put our heads together to work out the details of all the different mounts that need to be created for each item on the Antennae Arch. With so many different antennae and items to be mounted on this Arch, the numbering of each item was very helpful to keep them all straight and provide an easy shorthand for what was what. This is where we finished up on Friday so I will show you the whole antennae farm next week.
Nogva CPP Propeller Blades
While everyone else was busy prepping to move Möbius I took on the other job that needed to be done before the move which was to reassemble the Nogva CPP propeller blades. You may recall from previous posts many months ago that we removed the CPP (Controllable Pitch Propeller) blades and hub when we were cutting the hole in the Rudder that enables us to remove the whole prop shaft without having to remove the Rudder. Now the whole CPP propeller hub & blades needed to be reassembled now which is a fairly straightforward process as these CPP mechanisms are eXtremely simple but they are also very high precision fit and have critical rubber O-ring seals that need to be put in place just right. Each of the four prop blades are a single piece CNC milled from a solid billet of special bronze alloy which weigh about 20kg/45 lbs so they are a bit unwieldly to handle and get them to slide into the high tolerance fit into the hub. Like this. Uğur helped me in the beginning until he had to go look after moving Möbius so we thoroughly cleaned each part, put on a lots of new grease. Fortunately, there were two excellent student interns working at Naval this past month, Omer on the Left and Alp on the Right, and they were eager to learn about how CPP props work so they joined in and helped wrestle each very slippery and heavy prop blade into position. If you look closely in the photos above (click to enlarge any photo) you can see that each prop blade fits into a slot in the hub so they can’t fall out and will stay in place once they have been fully slid into place. Then the hub end can be slid in place to capture the other half of each blade and this is then torqued down with some thread locker on each of the 8 bolts. And Voila! Miss Möbius has her CPP prop all good to go. Viewed from the forward side looking aft you can see how there prop shaft itself is fully enclosed within the outer aluminium collar with the holes in it which thus prevents any errant ropes or fishing nets from wrapping around the prop shaft. The holes are where the water injected into the far forward end of the prop shaft exits back to the sea and keeps the prop shaft fully protected by fresh seawater inside the prop shaft log tube.
Kobelt Hydraulic Steering Oil Tanks
Last week we covered Uğur and Nihat building the two header tanks for the hydraulic oil supply to the Kobelt steering pumps.
This is the larger of the two tanks which I designed to hold about 52L/14 USG of oil to keep these two Accu-Steer HPU400 auto pilot pumps well fed and I was able to design it to fit just perfectly into the space above these pumps. This is a combination sight gauge and thermometer that makes it quick and easy to check the temperature and level of the hydraulic oil inside. And we recessed this filler pipe and vent cap into the wall on the hinge side of the Watertight door from the Swim Platform into the Workshop so it is easy to access but not in your way as you walk in and out. This is the small little 1.5 liter header tank on the Left that keeps the bronze Kobelt manual steering pump on the Right full of hydraulic oil. I was able to design this tank to fit nicely into the space underneath of the Main Helm Dashboard which hinges up out of the way for access and Cihan soon had this tank all mounted and plumbed into the Kobelt hydraulic system.
Speaking of our head Plumber Cihan, he was back on Team Möbius this week thankfully and was busy installing several other systems on Möbius including the equipment for the shower on the Swim Platform. Christine had picked up this very high quality bronze mixing valve at Ikea and Cihan soon had fabricated a bracket and mounted it up above the top of the Haz Mat locker where it will be super easy to access when needed yet well protected from the elements when not in use. Next week he will finish plumbing the Red/Blue Hot/Cold PEX water lines and the hand held shower wand. The large White wrapped hose is the supply for the Fire Hose that will also live here inside the Haz Mat locker. These long delayed Whale Gulper 220 Grey Water pumps finally arrived so Cihan was busy installing one of them in the Forepeak and one in the Basement where they will be used to pump out the contents of the Grey Water tanks to the exiting Sea Chests. NOTE: In practice we don’t use these very much as we almost always let the Grey Water from showers and sink drains go straight back to sea but when we do use the GW tanks in a marina for example, these pumps let us empty them next time we are out at sea.
Cihan also had time this past week to finish plumbing both of the VacuFlush toilets. This one is in the Guest Head and is now fully plumbed for the Fresh Water flushing water and supply water for the Bidet as well as the exiting Black Water. Ditto for this one in the Master Cabin Head.
These are both quite exciting milestones for Christine and me as they represent a new stage of the build as we move into such finishing work. And just outside the Master Head the pièce de résistance of Cihan’s work this past week was the installation of this bit of beauty; our Vanity Sink at the very front end of our Master Cabin. This unique sink is made from a solid clear glass casting which then has a iridescent coating of these beautiful blues. The drain cap is still wrapped in its protective film so it is normally adding its glimmering polished stainless steel glow to the whole look. And we think this faucet we found is equally unique and the perfect Goldilocks match for the sink it supplies.
There is a matching rectangular version of this sink and faucet in the Main Head/Bathroom where the all White walls create a complimentary yet different look. Can’t wait to see and share that with you in the next week or so once the Corian countertop is installed in the Head.
Back on the other side of the Vanity Sink the White gelcoat cabinetry is also getting closer to being finished. Bottom doors are now mounted on the Blum hinges and the countertop awaits the Corian that we hope will arrive in the next week or so.
The removable Teak floors for this Head and Shower as well as the Guest Shower are being finished up as well so I hope to be able to show you them being installed next week. Moving Aft to show you the recent progress in the Corridor which connects to the Guest Cabin off to the Left outside of this photo and then through the WT door into the Workshop and Engine Room in the upper Left background.
The area on the Port/Left Hull on the far Right of this photo will be my Office and “clean room” workbench which now has this gorgeous hunk of Turkish quarried Turquoise marble now in place. We ended up with a double order of this fabulous marble so I decided to use some of it in place of the Corian countertop we had originally specified. Should make an eXcellent working surface for me with plenty of storage drawers and cupboards above and below.
Seen from the other end just inside the WT Workshop door, you can see the large Aft Electrical panel full of circuit breakers for all four voltages; 12 & 24VDC and 120 & 230VAC is on the far Left side of the stairs leading up to the Galley and SuperSalon. This electrical panel will eventually be enclosed with an large labelled front panel and a hinged Rosewood and glass door. Upstairs looking Aft at the Galley, Omur has continued his relentless work to complete all the Rosewood cabinetry throughout Möbius. In front of the Galley our Dinette Settee is also nearing completion. Next up will be building and installing the large table here. That will be fun to show you as it moves in all three axis; Up/Down Z axis as well as fore/aft X axis and side to side Y axis as well as able to be rotated in any of these positions. Might sound excessive but it is “little details” like this which add so much joy to our lives when we are able to get things like table height and position just right, just for us as we use this table for everything from our main dining table, an office table for the two of us, a coffee table when relaxing and a bed when we have more guests than our cabins can sleep.
If you can see through the clutter of the work going on here you can see how this forward end of the SuperSalon is also starting to take shape. The large Rosewood slotted panel on the far Left will be hinged inside the opening behind it where the 50” SmarTV mounts. Helm Chair goes in the center of the Main Helm where all those wires are being tamed and then the stairs down the Master Cabin on the far Right.
ELECTRIC & ELECTRONICS:
As you can see, Hilmi has also been making good progress with his electrical work at the Main Helm. This week he and Selim have been busy wiring up the switch panel on the angled wall above the Forward Electrical Panel as well as the various controls mounted in the Dashboard of the Main Helm. The Furuno 711C AutoPilot control head is under that Gray protective cover in the center of the Dashboard with the Jog Lever to its Right and then the dual Kobelt control levers for Throttle and CPP Pitch on the far Right with the round Prop Pitch gauge above. Maxwell windlass control above the Jog Lever and the empty hole soon to be filled with the Vetus Bow Thruster joystick and the ACR Pan/Tilt searchlight in the upper Right corner. Lifting up the hinged Dashboard reveals more of Hilmi’s work as he starts to connect all those items as well as filling the Grey wire chases with the many wires that need to traverse from one side of the Main Helm to the other. This “handkerchief” triangular storage area is on the Port/Left side of the Main Helm with a matching on on the opposite side. We intend to use this one for a central Charging Station for the growing list of wireless electrical items that need charging. The two black panels you see in the back of this storage area are blocks of fused 12 & 24 VDC connections using Anderson PowerPole connectors to give us a single standard for all our 12 & 24 volt connections.
The rectangular hole is for the 120 & 230VAC receptacles.
More progress inside and behind this Forward Electrical Panel on the Right side of the Main Helm with the addition of the white mounted shunt, one of three, which is required for measuring current amps in this panel. Above the Fwd Electrical Panel Hilmi and Selim completed most of the wiring of the switchboards up on this angled top. The underside of the lower switch board shows the ready access to all this wiring. Top side shows the layout of all these switches. They are divided into the upper12 switches that control the High Water evacuation system which we hope we never need to use but is in just the right place here at Command Central if we ever do need it.
The bottom set of switches are for the exterior lighting and the labels should make that all self explanatory.
The uppermost switch panel has all the switches for controlling the Kobelt steering and propulsion equipment. To the untrained eye this may still look like a Medusa hairdoo but for those who have been following along and know wiring this is a “Beautiful Mess”!
Still in the early stages of wiring all these switches but Hilmi’s skills and attention to detail is already emerging on these two switch panels. Always a Team effort so Omur installed this multi pin socket into the top of this Rosewood switch panel where the Kobelt WalkAbout handheld remote control plugs in. A metal cap threads onto this socket when not in use. For a much more finished look, rather than install this receptacle from the top we decided to have Omur recess it in from the bottom with this mortise. This will give you an early idea of how these three switch plates will look in the end. And finishing up with this weeks electrical progress, the aft depth sounder has now been mounted inside the aluminium fairing block you saw Uğur making and welding in place a few weeks ago. This is the Airmar 600 Watt 520-5PSD transducer which provides the raw data of the bottom below us to the Furuno BBDS1 Bottom Discriminating sounder which gives us detailed graphics of the contours and material below us.
Uğur and Nihat were also able to get to this small but important job of providing external access to the inside of this Port/Left side Vent Box on the Aft Deck. The White plastic fitting below its mounting hole provides an easy to remove but fully sealed opening that I can reach through to …… …… access this shut off air damper on the Air Supply into the Engine Room. Normally this shut off is fully automated and controlled by an thermostatic switch that closes this damper when the engine is off or if there were to ever be a fire in the Engine Room. However in case this electrically automated motor should fail, you can activate this damper manually. Peering down the 3 meter rectangular supply air duct into the Engine room to show where this damper is bolted to the top.
Same damper setup is on the opposite side Vent Box for shutting off the Exhaust Air extraction vent.
Putting Humpty Dumpty (aka Mr. Gee) Back Together Again!
Another exciting milestone this week was that I finally started to put all of Mr. Gee’s bits and bobs back together again. After many months of doing all the prep work of cleaning, replacing, rebuilding, painting , etc. I was finally able to start actually assembling all those parts and putting Mr. Gee back together again in his better than factory new condition.
I know this is not of interest to many of you so feel free to skip ahead to the end while I take the others on a quick tour of Mr. Gee’s transition.
As you can see Mr. Gee is now all painted in his final colours of Burgundy Red for all the cast iron parts and silicone based aluminium paint for all the cast aluminium parts. This past week I was able to tackle the next metal parts; all the copper and bronze pipework which transports all of Mr. Gee’s the coolant water and oil to where it needs to go.
As you can perhaps tell from this photo I started by using paint removing gel and then sandblasting all these parts thoroughly to remove the almost 50 years of accumulated paint, grease, oil and dirt. I considered going with the quite nice matt lustre left from the fine sandblasting sand but after some experimentation I decided that a brighter look left from wire wheeling the copper and brass, which you can see the beginnings of here, was more in keeping with the finished look I thought most befitting of Mr. Gee and Möbius’ Engine Room. So I brought out my full compliment of WMD’s, Weapons of Mass Denuding, including wire wheels of various sizes in my angle grinder, benchtop grinder and Dremel tool and spent several days and knights bringing all these copper pipes and their bronze end fittings to an even bright lustre. Keeping this beautiful bright look was the next challenge as copper, brass and bronze all tend to oxidize quite quickly and loose this look. So I cleaned them all up with acetone to remove all the leftover grime from wire wheeling and my fingerprints, hung them all from poles spanning the ceiling of the paint booth I had created and sprayed them with 2 separate coasts of clear AlexSeal polyurethane which I have had great success with for many years. The photos fail to capture how great this clear coat worked but I am eXtremely pleased with both the look and how well protected these surfaces all are now and for the next few decades. If you were here last week you might remember that I had given Mr. Gee himself two coats of the same clear polyurethane so he too is now very nicely all plastic coated. While much of this is just cosmetic there is a very real pragmatic benefit I’ve found with having such surfaces on my engines and mechanical parts which is that I can see any leaks or even loosening nuts SO much sooner and these surfaces are all SO much easier to keep clean so I was quite willing to put in all this extra time, effort and expense. Plus, quite frankly, Mr. Gee and me are worth it! A few weeks ago I had found the time to clean and paint Mr. Gee’s massive, almost 150 Kg flywheel so I had Uğur lift it up to my Workshop using the forklift Where I could then use my handy dandy 2 ton hydraulic lift to finally install the flywheel on the end of the crankshaft. Which in turn let me bolt the outer flywheel housing onto Mr. Gee.
Next week we will move Mr. Gee onto the Aft Deck of Möbius where I can then bolt the Nogva CPP Gearbox to the SAE1 flywheel housing to complete the full propulsion package. You can see the SAE14 flange I have now bolted to the flywheel and each of those inner semi cylindrical cogs will mate with the rubber drive ring on the Nogva Gearbox.
When I was cleaning and painting the flywheel I masked off the six sets of markings on the outer circumference of the flywheel and now you can see why. This little window on the top of the flywheel housing allows me to precisely set Mr. Gee to TDC (Top Dead Center) for each cylinder which you need to do to set the exact timing of the open/close of the valves and the timing and advance of the fuel injection.
Now the fun begins as I carefully remove all the masking taped areas and started installing things like the two cast aluminium valve covers, upper cast aluminium water manifolds on each cylinder head and the single manifold on the bottom of the cylinder block. Followed by the Intake and Exhaust manifolds on this same Starboard/Right side of Mr. Gee. Test fitting the dual thermostat housing on the end of the front water manifold and the coolant header tank. Next week I hope to start populating this Port/Left side with all its gear including the whole fuel pump and injection system which mounts to those two circular clamps you see here. BTW, for those who would find it interesting, this is Mr. Gee’s “service side” where you do most of the day to day work when starting and maintaining him as this is where things like the decompression levers, fuel priming levers, water pump, fuel pump, oil dipstick, temperature and pressure gauges for oil and coolant, etc. Hence this is the side where I located the door into the Engine room and have the most access on this side as you will soon see when we mount Mr. Gee into his new home and Engine Room.
If you made it this far I hope you took my advise to get a good beverage and comfy seat or you stopped along the way to do so. I really do appreciate you taking the time to follow along and join Christine and I on this latest adventure and we both look forward to getting your feedback with the questions and comments you put in the “Join the Discussion” box below.