New Year – New Boat–New Baby?  Progress Update XPM78-01 Möbius Dec 30-Jan 03, 2020

New Year – New Boat–New Baby? Progress Update XPM78-01 Möbius Dec 30-Jan 03, 2020

First and foremost Christine and I, along with everyone on Team Möbius here at Naval Yachts, we want to wish all of you a VERY Happy New Year and the hopes that 2020 will be the best circumnavigation of the sun for all of us.  It is shaping up to be a VERY good year for us as we all work relentlessly towards launching the very first XPM and our new home Möbius in the next few months. 

W&C New Years bow shot KissingWhile it does often remind me of that saying “when you are up to your neck in alligators, it is hard to remember you are there to drain the swamp”, this adventure continues to be an awemazing experience for us and very much remains a labour of love and combined work of art and engineering. 

And while we gladly chose to use a “pay it forward” approach to this blog and do our best to openly share all aspects of turning our vision into the reality of the very best Goldilocks just right, just for us boat, we REALLY appreciate the thousands of you who chose to subscribe and join us on this grand adventure.  It means a great deal to us and you add a huge value to the whole experience so a very heartfelt THANK YOU! going out to all of you as we get this new year and this new decade started.


Click to enlarge the photo to see the first of many New Year’s Eve kisses standing in front of our already beloved Möbius with some of the crates in front that are piling up as more and more new equipment arrives. 

When you are married to your best friend and your Captain who also happens to be the most Beautiful person you know, you take EVERY chance you get to kiss her!

IMG_20191229_175105Naval Yachts sent everyone home at noon on New Year’s Eve and reopened on Jan 2nd so we all enjoyed a 3.5 day work week.  Christine and I enjoyed the chance to have time together to engage in deeper discussions about the thousands of decisions needing to be made and new learning about such scintillating topics as NMEA 2000 network topologies so we spent much of our “time off” comfortably sitting in front of our large 50” monitor at home to have all our reference info easily displayed for both of us to see, point to and modify.  Different strokes for different folks right and being the crazy couple we are, this was great fun for us.


In the foreground you can see that Christine is getting lots of help from Commodore Barney aka the Yorkshire Terror and if you click to enlarge and look closely on the couch behind Christine’s back you can just make out Ruby the Wonderdog who is also supervising her work.


IMG_20200104_173229New Year’s Day dawned with clear blue skies and sun to light up the mountains which surround us and showed off their freshly snow covered tops.
IMG_20200104_173247Not what many people imagine when they think of Turkey but we love this country and even more so her people, food and sights.  We are very anxious to move aboard Möbius and get back to life at sea but we will also miss this special place that has been our home based for over two years and our Goldilocks location to built our Goldilocks boat; just right, just for us.
IMG_20200101_170448_MPWe did take a bit of time off on New Year’s Day to go for a long walk to some of our many favorite spots along the Med coastline that is only a few blocks away and a large newly constructed park along both sides of the new inlet they are putting in which will eventually have a large superyacht marina in the waters you can see here.
IMG_20200101_164245If we were to have any regrets it would only be that we don’t get or take enough time to enjoy our incredible surroundings every day.  This spot along a beachfront walk is at the very far West end of Antalya and only a few blocks from both our apartment and Naval Yachts in the Antalya Free Zone. 


In the background you can see how the city of Antalya stretches along the crescent coastline to that point you can see in the distance in the upper middle of this photo.

All very beautiful and fun BUT even we couldn’t top the news the next day that Naval Yachts had expanded VERY significantly with the arrival of the very first girl in the Dinc family for several generations.

Ida Dinc   Mom 01-02-2020Meet the newest member of the Dinc family; Okyanus Ida, born Jan 02, 2020 at 2.65kg.  Baby and Mom both doing great.  Dad Baris, we’re not so sure?! Smile

Welcome to this most awemazing world Okyanus Ida!  Oh the places you will go and the Love you will know.

Well, I certainly can’t top that but let’s get back to boat building shall we?

ELECTRICAL:

IMG_20200102_152757I’ll start with a brief update on what the Sparkies or electricians have been up to this week and see if you can guess what Hilmi, our electrician seen here driving the forklift, is moving up onto the front deck of Möbius?

Hint, they are VERY heavy!
IMG_20200103_104728Many of you will have guessed correctly that these are the two pallets full of our batteries.  I know many of you have been patiently awaiting my Tech Talk discussing our new battery choice and the details of our whole DC system and I’m afraid I need to test your patience a bit longer as I just have not had the time to finish that article, but it should be done and posted within the next week or so.
Untitled-1The not so well kept secret many of you have already figured out is that we changed the battery type we are using for both the 24V @ 1350Ah House Battery Banks and the Gardner Start Batteries from OPzV Gel type to Microcell Carbon Foam batteries by FireFly International.


XPM Electrical System

This graphic which you’ve seen in previous posts will give you the high level view of the overall Electrical System on XPM78-01 and I’ll be doing a much deeper dive into these components in future posts.
IMG_20200103_104603Back onboard, Nihat is working on the cross members for what we are calling “the Victron Wall” as it will soon have all the big blue Victron boxes mounted which include:

  • 3 Multi-Plus 5kW 220V Inverter 120A Chargers
  • 2 Multi-Plus 3kW 120V Inverter 70A Chargers
  • Isolation Transformer
  • Centaur 90-265V 50/60Hz “World” 24V @ 60A charger
  • 2 Orion DC-DC 24-12V @ 7A  converters
  • 14 100/30 MPPT Controllers

IMG_20200103_125012With apologies for the poor quality this photo of the sketch onboard will show you the basic layout for this wall and some of its components.  The main high amp DC circuit distribution panel will be in the middle flanked by the Victron components. 

The 14 MPPT Controllers will mount on the other side along with several other DC related equipment.
IMG_20200103_124553One of the many advantages of building wtih aluminium and having this cavernous Basement area under the whole SuperSalon floor is that we can put in these “walls” anywhere we like to create an enormous amount of surface area for mounting equipment. 


Having so much area means we can space the equipment out to make access eXtremely easy and in the case of heat producing components like these Victron units, keep them much better cooled. 

The whole Basement is also fully ventilated wtih both passive and active fan assisted ventilation which is separate from the same level of ventilation in the integral  Battery Boxes which you can see on the Right.


IMG_20200103_171724_MPJust about done, Hilmi  with his back to us helps hold in the flatbar cross member that will soon be home to some of the 14 MPPT controllers.

PLUMBING:

Cihan was moving too fast for me to catch up with this week I only caught him in this one shot to show you some of his latest handiwork with the plumbing on Möbius.  This shot is taken inside the Engine Room looking at the forward Starboard/Right corner. 

IMG_20191230_163411

Here he is connecting one of the water supply hoses to fill the Starboard ER water tank.  Intake Sea Chest is right behind him and you can see the white perforated tray running across the WT Bulkhead which will soon fill up with more water hoses.

Nogva CPP Servo Gearbox in the bottom Right and Mr. Gee our Gardner 6LXB will soon be bolted in front.

Whale Gulper Grey IC box photoEvidence of Cihan’s work is also evident up in the Master and I think some of you will be quite interested to some of you how we are going to handle draining shower and floor in the Master Cabin so let’s take a look.  We are going to try out this relatively new Whale Gulper IC drain pump system.  With our floors sitting on top of all the integral fuel/water tanks it is challenging to be able to use gravity to drain the water from the floor of the shower and the Head and this Whale IC system is the perfect solution.


If you click to enlarge the photo (works on all photos BTW), you can see the diagrams showing how this works.


Whale Gulper Grey IC components photoThis model handles two drains by having each drain hose go straight into the round yellow 2 way manifold you see on the right.  Inside is a small electronic water sensor which is the IC Intelligent Control in the name and when it senses water it sends the signal to the Gulper diaphragm pump on the left to turn on and pump the water out of the manifold and into either the Grey Water holding tank or Sea Chest.  When there is no water in the manifold sensor it shuts the pump off.

IMG_20200103_125154Here is what the drain looks like mocked up on the floor in the Master Cabin Shower.  There is a matching one off to the Right just out of this picture which will drain the floor in the adjoining Head/Bathroom.  A hose will connect the Yellow manifold to the horizontal Grey fitting coming from the shower floor.


You can see the Yellow 2 way manifold hiding  in the center background and on the Left atop the White S trap is where the drain in the shower floor will be.  Floor height is raised in the Heads to provide enough drop to gravity feed the manifold.  The pump will mount on the other side of the WT Bulkhead in the Forepeak so the drain will be completely silent.

All very simple and automatic compared to the more common marine solution of having to turn on a pump manually or building in a shower sump box with a float switch and centrifugal pump which typically clogs very easily and requires frequent maintenance.  Music to my ears and one of the XPM theme songs; Low Maintenance!

ALUMINIUM WORK:

IMG_20191230_163334Uğur, Okan and Nihat who is pictured here, continued where they left off last week putting in the grid for the removable Alucobond sheeting on the walls and ceilings of the Workshop and ER.  You can see the aluminium L-bars in the aft most end of the Workshop are now in place and ready to receive the Alucobond sheets.


Nihat is also putting in some of the last bits of EPDM insulation foam on the Aft Transom wall where Cihan will soon be installing the two shelves for the Accu-Steer HPU400 Steering Pumps to mount directly overtop of the Rudder Post and Tiller Arm Head which sit right about where Nihat’s knee is.

IMG_20191230_163338Rotating about 90 degrees to the Left looking at the Starboard/Right side of the hull we see that the L-bar mounts are in place and ready for the Alucobond. 

The Black/Yellow tool box and Blue bucket are setting atop the AL Workbench and cable trays on the ceiling and Port side wall are starting to fill up with electrical cable and plumbing.
IMG_20200102_112233First two of the AlucoBond panels to be fitted along the Starboard/Right side of the ER and overtop the Day Tank.  Sticks being used to hold the individual panels in place while they are being fitted.
IMG_20200102_113116_MPSporting his fashionable New Year’s haircut, Uğur puts in the next panel Aft of the two above.
IMG_20200103_141407Same story on the opposite Port/Left side looking Aft from the WT door from the Guest Cabin into the Workshop.  The walls are next in the queue to have their Alucobond panels fitted.
IMG_20191230_125355Pardon the poor focus but this is the system we will use to fasten all the Alucobond panels to the L-bar.  Self drilling and tapping screws which have that special brass washer that is threaded on the outside circumference and the chrome cap is threaded on top.
IMG_20191230_125440Looks like this all assembled and makes for a nice finished look.

Whenever I want to remove one of these panels to access what’s behind I just twist off the caps and undo the screws.  KISS, Keep it Simple and Safe.

GUEST CABIN/OFFICE CABINETRY:

IMG_20191230_114504

I tend to save the Cabinetry Team’s work for the end because otherwise their work with this Rosewood tends to steal the show and with doors like this make that quite easy to understand.

But now let’s go check in with Omer, Omur and Selim and see what’s new this week.
IMG_20191230_114509Omer is in charge of the cabinetry in the Guest Cabin, Head, Shower and Corridor Office and we find him working on that “Swiss Door” we showed you last week when he was fitting it into place in the door frames onboard Möbius.  Now he is trimming the solid edges with their radiused corners and rabbits/grooves for door seals.
Swiss Door exampleThere are French Doors, Dutch Doors, Pocket Doors and so we’ve come up with this Swiss Door moniker for the two doors we’ve designed into the boat, one in the Guest Cabin and another in the Main Cabin.  Both of ours are off the boat right now and this type of door is not well known but I was able to find this shot online that shows how they work.  A single door which swings shut on two different doorways.

We figured these doors are a bit like a multi purpose Swiss Army knife and hence Swiss Door! 


We had one on our former sailboat “Learnativity”, the source of a lot of ideas we are bringing with us onto Möbius.  They eliminate one or more doors so a big weight savings and cleans up areas on the boat where you might have multiple doors all competing for space and swing room.  More KISS


IMG_20191230_163507On Möbius here is what that door looks like looking out through the entranceway out of the Guest Cabin into the Corridor where my “Clean Workbench” office runs along the Port/Left hull.  Swiss Door on the Right now closing off the Head/Bathroom, Shower on the Left.  Door is hinged on the far side nearest the Corridor.
IMG_20191230_163636Stepping out into the Corridor and looking forward to the stairs that lead up to the SuperSalon shows that same Swiss Door with its hinges about where the blue tape is.  Your imagination shouldn’t have too much trouble seeing how it will swing open from here and shut against the door jamb in the foreground when our Guests would like some privacy or when Christine is working at her Office in there and wants to keep her pesky husband out!
IMG_20200103_125913Back in the Cabinetry shop these are some of those door frames and door jambs ready to be glued up and finished.
IMG_20200103_125919Laminated cores wrapped in Rosewood veneer and solid edges makes these both super strong and beautiful.  Not that I’m biased or anything.
Guest Cabin V2 Fwd Stbd cornerOmer also worked on finishing up the Pullman Berth inside the Guest Cabin and for orientation here is a rough rendering of what the Guest Cabin looks like with the Pullman Berth hinging out of the Upper Right side of the back wall which runs along the Starboard/Right hull.  It folds up to be out of the way as it is here and then easily folds down like Pullman Berths on trains and ships or a bit like a Murphy  bed in homes.
IMG_20200102_163107Here Omer is working on the single bed sized frame that folds down to make the Pullman Berth. 
IMG_20191231_114700_MPFlipped over to show how the mattress will be fit inside this frame and stay secure as it is folded up and down.
IMG_20191231_114712Before he glued it up, Omer took time to show this good example of how the biscuit joints work to create super strong glued joints.

But what are those five holes for???
IMG_20191231_114019Aha!  Yunus, our Stainless Steel guru has whipped up these SS hinges for the Pullman.
IMG_20191231_114058One mounted in the lower sides of the outer cabinet which the Pullman Berth frame sits inside of.

Vent grills on the top are where the cold/hot air will come into the Guest Cabin/Office.
IMG_20200103_105537With the Pullman bed frame all glued up and sanded, Omer added these strips of Beech to provide that thin gap running inside the corner between the strips and the frame sides.  This is where they will tuck the leather that wraps around the outer surfaces of the Pullman and are pulled tight.  More on that in coming weeks as the interior finishes begin to be added.

GALLEY COUNTERTOP GARAGES:

MOBIUS_SALOON_RENDER (1)Not to be outdone, Omur and Selim were also hard at work on the cabinetry for what we call the Galley Garages that set atop all the Turquoise granite countertops as you can see rendered here.


Dinette or Settee in the foreground with Galley behind on the Left side, entry door and stairs down from the Aft Deck on the far Right side blocked a bit by the tall twin fridge cabinets and Lounge on the far Right.


MOBIUS_SALOON_RENDER (4)This overhead shot puts the whole SuperSalon into perspective.  Stairs down from the Aft Deck and second set down to the Corridor and Guest Cabin in the bottom Right.  Continuing counter clockwise; Lounge area with Eames chairs, Main Helm chair center Left, stairs down to Master Cabin upper Left, Dinette/Settee, Galley in upper Right corner with Garages wrapping around all the countertops.


IMG_20191230_114618Omur checking the fit of the Garage doors on the Garages that run along the Stbd/Right side windows as prepares for laminating the Rosewood veneer to finish these off.
IMG_20191230_114647Same set of Garages seen from the back edges that will run along the 28 mm glass side Pilot House windows.  The cut-out where his hand is are where the vertical aluminium I-beam frames and window mullions set.
IMG_20191230_114731Selim has been busy similarly finishing off this set of Galley Garages that run along the seatback of the Dinette/Settee.  The glue bottle will help give you a sense of size and scale of the interior.
IMG_20191230_114740Same glue bottle inside this other set of Garages which run along the Aft windows to show how these interior volumes vary.

You can see how Selim and Omur have finished off all the solid Rosewood edging around each door frame and have carefully filled and sanded all the outer surfaces flat and smooth.  All this is in preparation for the final step of applying the carefully matched Rosewood veneer to all these exterior surfaces.
IMG_20200103_105739 If you check out the shapes of these Garages in the renderings above and notice the mitred corners where each set meet and make the 90 degree turn, you can appreciate how much of an Origami like puzzle it is to figure out the shape of the single piece of Rosewood veneer needed to wrap around all these exterior surfaces.

Here is on Garage’s veneer all carefully selected and taped together ready to be laminated to the cabinet behind.
IMG_20200103_172335But just how are they going to manage to glue this single sheet to all those surfaces keeping everything lined up and getting the veneer tightly squeezed against the cabinet surfaces?

Clues to the answer lie in the strips of black tubing you may have noticed in a few shots and this one on the left.  And you will also note how the open end of this cabinet has all been stuffed full of foam?
IMG_20200103_125851Hmmmm, more of that black tubing running around all the corners and edges ……….
IMG_20200102_113610More clues here with this vacuum gauge……
IMG_20200102_113601Which is part of this big vacuum pump and what you see in the background answers the riddle.

Yup, they are going to vacuum bag all the Garages and glue the Rosewood veneer on in a similar way in which the new high tech composite fiber such as Kevlar are being laminated in their molds.
IMG_20200103_172200Each cabinet takes it turn being wrapped up in this special vacuum forming plastic and you can now see the purpose of that black tubing……..
IMG_20200102_113441…………. and the foam is to keep the plastic sheeting tightly sealed as it goes around corners and the foam is to keep the plastic from being sucked inside any openings on the ends as they take the vacuum up to about 600mmHg. 
IMG_20200102_113355That’s a LOT of vacuum, and you can see evidence of that in this shot where the veneer spans one of those cut outs for the window mullions we saw earlier and notice how the veneer is being pulled down into the vacant space by the vacuum inside.
IMG_20200102_113333Hakan is helping Omur to monitor the progress and keep everything sealed as they pull down more and more vacuum on this largest of the four Garage cabinets and use the internal vacuum to apply huge amount of evenly distributed pressure on the veneer to adhere it perfectly flat against the inner core of the cabinets.
IMG_20200102_113427This shot looking down the full length of this cabinet the reflection helps show how well the vacuum pulls the veneer tight and flat against the underlying cabinet.
IMG_20200102_162832The fully vacuum bagged cabinets are left for at least 8 hours for the glue to fully set and then the vacuum is released and the plastic pulled off.

Now they can remove all the black plastic tubing and foam.
IMG_20200102_162911The overlapping veneer can now be easily trimmed off with a sharp knife and others are cleaned up with a hand router.
IMG_20200103_105606Like the caterpillar that finally emerges from his cocoon and becomes the most beautiful butterfly our Garages emerge from their plastic cocoon to reveal THIS beauty! 
IMG_20200103_105620I had to touch it to make sure it was real.
IMG_20200103_105642I could stare at this all day and this is the ROUGH out of the bag finish!
IMG_20200103_105824And just wait till you see what these Garages look like once they are all joined together in the Galley sporting their swirling Rosewood grain all matched up.  Omur showing us some of how that magic happens as he checks out the next pieced together sheet of matching Rosewood for the Garage which runs perpendicular to the long one on the ground to the left that we just watched emerge from its cocoon.
IMG_20200103_105845Selim helps to carefully position the veneer in just the right spot which is marked off on the tape to register with a matching mark on its Garage cabinet as it gets ready to be vacuum bagged.
IMG_20200103_125804A closeup of the long cabinet showing how the veneer and the solid edging match up.
IMG_20200103_125815Next step is to radius all these corners with a 5mm router bit for that “quilted” look I so like and has been done throughout all the cabinetry on Möbius.

But WAIT!  There’s MORE!!!!

IMG_20200103_105149Upstairs in the Finishing Shop, that team has started to apply the 5 coats of clear PU varnish to some of the cabinetry that has recently been finished so let’s finish off this week’s Progress Update with a peek in there.
IMG_20200103_105210These are some of the cabinets from my Clean Workbench/Office in the Corridor we saw earlier.  Check out how well the Rosewood contrasts with the inner Beech surfaces.
IMG_20200103_105225Only 2 of the 5 coats of PU and already looking awesome to my eye.
IMG_20200103_105241Here is the cabinet you may remember seeing a few weeks ago inside the Guest Cabin Head with the little White sink on top.
IMG_20200103_105249Some might say why bother to finish off areas like this bottom of my Office cabinet with the groove for the indirect LED floor lightning strips when only a mouse would be able to see it?

Why?

Because I know it’s there and it makes me VERY happy knowing it.
IMG_20200103_105158But I don’t think anyone will question why we are going to such lengths and expense to use Rosewood for all our interior when you see results like this starting to emerge.
IMG_20200103_105205_MPMother Nature is as close as I come to religion which is a big part of why I am so filled with profound joy when I’m out at sea.

IMHO, she outdoes even her awemazing self with examples like this.  Do your eyes and your soul a favor and click on this image, ideally on a very large and very good screen and join me as I just sit in awe as I stare at this perfectly flat surface that convincingly fools my eye into thinking it is a beautiful brown curtain being pulled back to reveal that creamy depth inside.

NOW you might understand why I refer to Möbius as a combined work of art and engineering.
I can’t top Mother Nature so I will leave you here as I go back to stare at her latest magic.

Thanks for joining us again this first week of 2020 and year of the launch of XPM78-01 Möbius.

-Wayne

Santa Alive & Well in Turkey!  XPM78-01 Möbius Progress Update Dec. 23-28, 2019

Santa Alive & Well in Turkey! XPM78-01 Möbius Progress Update Dec. 23-28, 2019

Lest you be wondering, I can assure you that Santa is alive and well in Turkey and as you’ll see in this week’s update, I have a preponderance of evidence to support this claim  So many new things have shown up this past week I won’t be able to cover them all but I’ll show you most of them as well as the progress aboard Möbius this last week of 2019.

As we make the final push towards launching the first XPM the demands on all our time goes up so we don’t get too many days or hours doing anything but working on Möbius but Christine and I did stay home from Naval Yachts on Xmas Day and although we both spent the day working on XPM related things we treated ourselves to working on things that needed our simultaneous attention and so we spent a great deal of the day in comfy chairs we pulled up in front of a big 50” monitor so we could discuss and learn things together, which for us is great fun.  We are usually so busy working independently, often with Christine at home and me at the shipyard that we only get our evenings to discuss and work on things together so it was a real treat to have the whole day to ourselves.

IMG_20191225_102827Well, mostly to ourselves, we did have more evidence of Santa’s present in that we also spent the day with two of his best elves. 

IMG_2161If you click to enlarge this photo you’ll get a kick out of that little wood plaque that Christine picked up at a little market in our neighborhood.  Even though “Iyi Seneler” is Turkish for Happy New Year, you can see that somehow Santa, Frosty and Rudolph the red-nosed reindeer are a big part of this time of year.
I’ll keep you waiting till the end for all the other evidence of Santa so we can dive right into all the progress that all the other elves on Team Möbius accomplished.

PLUMBING:

IMG_20191211_124838You may recall seeing these two water manifolds which Cihan expertly put together using PPR/PVC fittings and ball valves a few weeks ago.
IMG_20191227_101239This week Cihan welded in the vertical flat bars and mounted both manifolds along the Starboard/Right side hull that runs alongside the Engine Room Enclosure walls on the left here and just aft of the Day Tank mounted on the WT Bulkhead with the Guest Cabin on the other side.


You can also see that more and more of the AC and DC wiring is showing up in more and more areas and those white perforated cable trays are rapidly filling up.


IMG_20191223_114519Several of you have asked about the PPR pipe and fittings being used onboard and if it is the same as PVC.  It is similar but PPR pipe is a Pipe made of Polypropylene Random Copolymer (Polypropylene Random Copolymer type 3 to be exact).  The PPR pipes are very common throughout the world and are mainly designed for the distribution of hot and cold water which is what we are using them for aboard Möbius.


Unlike PVC which is most often glued, PPR is a thermal setting plastic so special heating tools are used to melt or weld fittings to the pipes for a very rapid and leak free joint.  One other nice thing about the PPR fittings we are using is that they have SS threads moulded into the fittings such as this 90 degree elbow which makes


IMG_20191223_114509And some of you were also asking about the vibration dampening mounts we are using to mount equipment that doesn’t come with its own such as in this case the three green circulation pumps you can see in the background which move the hot water through each of the PEX tubes in each zone/cabin.  These are simple generic mounts with a SS stud on each side with thick rubber vulcanized between the two. 
The rubber also keeps all the equipment electrically isolated so that we can be sure that all electrical current onboard only travels through the wires we install and there is no current flowing through the aluminium hull or other components.

ALUMINIUM WORKS:

IMG_20191223_120511The Dynamic Duo of Uğur & Nihat continued their relentless work on aluminium based projects  not the least of which was finishing the installation of the prop tubes.  Hiding under the protective wraps is the big Nogva CPP propeller as it waits for the installation of the Nogva Servo Gearbox in the Engine Room.

This shot also shows the shape of the prop tunnel which enables the prop to sit up higher and thus reduce our draft below the waterline to a mere 1.2m/4ft which is eXtremely shallow for boats of any size let alone one this large.  This becomes a huge advantage for us because we can make it through shallow passes and often be the only boat that can make it inside tropical atolls or go up rivers and fjords that other boats can’t.


The other benefit of the prop tunnel is that we can keep the prop shaft and motor closer to level and not tilting down too much.  The closer a prop shaft is to being parallel with the waterline the more efficient it is.


IMG_20191223_183247Last week you saw Nihat & Uğur start fabricating this door for the HazMat locker on the Port/Left side of the Swim Platform and this week they finished it and mounted it on its hinges.
IMG_20191223_183257They are waiting for the dogs/latches to arrive and will install those with their handles so this door can be fully watertight.

This door is the only opening in the Hazmat locker so it s is fully sealed off from the rest of the boat enabling us to safely store flammable or hazardous materials such as diesel fuel, paint thinners and the like.
IMG_20191226_114651Taking a break from welding fumes Uğur and Nihat turned to building the ceiling grid that will be used to mount the removable ceiling panels in the Workshop and Engine Room which are both subject to a lot dirt, dust and fumes over the years and I wanted them to have a tough, fireproof, light reflecting and easily cleaned surface.
ALUCOBOND 2We are using Alucobond Plus for all the ceiling panels in the Workshop and to cover all the walls and ceiling in the Engine Room. 
AlucoBond samples 2Alucobond comes in plywood size sheets which is easily worked with carbide tipped woodworking tools such as table saws, routers, etc. and the outer aluminium surfaces are painted white and delivered covered with a protective peel-off foil that will be removed just before we launch and protect these surfaces in the meantime.

Perforated aluminium sheetsThe more traditional wall and ceiling coverings in the Engine Rooms of most boats is aluminium sheets that are perforated with hundreds of small holes to help dampen sound a bit but I find them to be a real bear to clean after a few years accumulation of dust and oil in the air starts to fill all these pores. 

AlucoBond samplesAlucobond’s smooth flat white (in our case) surfaces are extremely easy to keep clean and reflect light well so visibility is much greater as well.  They also add to the fire rating of the Engine Room so what’s not to like?!
IMG_20191226_114653Okan pitched in as well to help align the aluminium L-bars which they are fastening to the ceilings and walls to provide smooth flat mounting surfaces for the Alucobond to be screwed to.  These panels will also help protect the wiring and plumbing running across the ceiling but be easy to remove whenever I want to access these areas.


Mounting all the Alucobond is very time consuming so you will  be seeing a lot of Alucobond in the coming weeks as all these panels are installed.


IMG_20191227_101615Speaking of the Engine Room, look who decided to pay his first visit there?  None other than Mr. Nogva CPP Servo Gearbox.  This shot is taken standing at the forward end of the large hatch in the Aft Deck between the two Vent Boxes and looking down into the aft end of the Engine Room.
IMG_20191226_130128Moving to the other end of the hatch looking at the forward wall of the ER you can see where Mr. Gee will soon be living bolted up to the Nogva Gearbox., both of which will rest on mounting struts coming off the thick longitudinal AL engine beds.  The two vertical pipes in each forward corner of the ER are Sea Chests; Exiting on the Left and Intake on the Right.
IMG_20191226_114732Mr. Nogva is resting on a wood pallet spanning the two Engine Beds for now as the mounting struts have not been made yet but you can see how it will soon drop down from here to connect its output flange to that red flange on the end of the prop shaft on the far right.
IMG_20191226_114859This is the input side of the Nogva and that round SAE1 bolt pattern will soon be bolted to the matching housing on the aft end of Mr. Gee our Gardner 6LXB engine.  The beefy cogged black rubber disk is a Centamax flexible coupling that the flywheel of Mr. Gee will drive. 
Centamax flex couplingWe are using a slightly different model but this image shows how the three parts of a Centamax coupling fit together.  The outer aluminium flange is what bolts to engine’s output flywheel and those inner aluminium fingers mesh tightly with the matching groves in the thick black rubber disk which is attached to the keyed flange in the center which transfers the torque and power to the input flange of the CPP Gearbox. 


Centamax are eXtremely heavy duty flex couplings which significantly reduce any vibration or noise in the propulsion system and help keep everything running smooth and quiet.


CABINETRY:

The Cabinetry Team mostly worked in the Cabinet workshop this past week so let’s head over there and see what Omer, Selim and Omur are up to.

IMG_20191211_103715Two weeks ago, you may recall seeing this shot of the countertops being fitted into the Guest Cabin Head/Bathroom. 


VacuFlush toilet will rest on the roughed in plywood platform you see on the floor, sink on the right and the upper walls will be covered with leather panels.


IMG_20191223_115639Once all this was fitting up to Omer’s high standards, this week he brought all the parts back to the cabinetry shop to do the final sanding and prep work to send them up to the finishing shop to be sprayed with multiple coats of clear protective Polyurethane varnish.
IMG_20191223_120427The cupboard below the sink is also here to be finish sanded before being sent up to the spray painting booth for its coats of PU varnish.
IMG_20191224_103623As is this bookshelf from my Office area.
IMG_20191224_144749_MPMoving on to other Rosewood parts for my “clean room” Office area outside the Guest Cabin, Omer is gluing up the solid Rosewood for my infamous “Blue Horizon Line” and hand hold moulding.
IMG_20191227_111927Once the glue sets he runs these long strips of Rosewood through the shaper to create the inside radius corner where your fingers grab hold.
IMG_20191226_115702

On the right is the beginning of one of our “Swiss Doors” as we call the doors which close against two door jambs 90 degrees to each other.  There are French Doors, Dutch Doors so we thought we would call these doors which do double duty in a kind of “Swiss Army knife way” Swiss Doors.
Corridor workbench   StairsHere is how they work.  In the case of this door, in the position in this render it closes off the the Guest Cabin Head/Bathroom.

Note: that for clarity in this rendering I have removed the Shower that normally sits where this camera view is taken from.

My Clean Room workbench/office is on the left and stairs up to the SuperSalon in the center.
Guest Head Shower wo Walls - CopyNow you are sitting atop that workbench above and looking across to the Starboard/Right side and into the Guest Cabin with the Head behind the wall on the Left side and the Shower behind the wall on the Right. 
Door hinge is on the Left side so when the door is swung open from closing off the Head, it closes against this Cabin entryway and gives privacy when heading in/out of the shower or whenever else wanted.

Simple, elegant and allowed us to eliminate two other doors in this area alone.


IMG_20191226_181343A bit later, that same door, now flipped over with its solid Rosewood edging being applied.  These interior doors are foam cored and built from the new super lightweight Poplar marine plywood which is helps our weight saving budget tremendously.


IMG_20191227_150113Lower portion of the door on the Left will be covered wtih Rosewood veneer seen on the right.

The upper framed area will  have a leather panel inserted to match all the upper wall surfaces above the Horizon Line running  throughout the boat.

Last  week we saw Omur and Selim start building the liners for inside surfaces of all the aluminium hatches we designed and built in house here at Naval Yachts.  Several of you asked about how the lamination process worked so here are a series of shots to answer those questions.


IMG_20191220_103321

As we saw last week, Omur and Selim laid up the initial shape and size using the hatches themselves to form the first few layers.

IMG_20191223_115720Once the glue had set they slide the inner lining out of the hatch and bring them back to the workshop to start laying in the next round of laminations which provide the base for the Rosewood solid edges and top lamination.

Omur starts by fitting the next layer.
IMG_20191223_115755The material being used for the laminations is a special type of thin and easily formed wood which is itself a series of laminations.
IMG_20191223_115846_MPWith the next lamination piece ready Omur spreads and even layer of waterproof marine PU glue on all the surfaces.
IMG_20191223_120025Sets the lamination in place with the end against the block he has previously temporarily tacked in place to match the length of the lamination strips.
IMG_20191223_115741A scrap bit of plywood with a radiused corner is set in place to help apply even pressure when the lamination is clamped and also push the lamination fully into the radiused corner.
IMG_20191223_120130Clamps in both directions press the lamination tightly against the hatch liner.
IMG_20191223_120232More clamps are added to apply pressure all along the lamination and it is left to cure before the next lamination is applied.
IMG_20191224_114313Rinse and repeat to make all ten of these hatch liners.
IMG_20191226_181359While Hatch Liners dry, Omur and Selim move over to the countertop Galley Garages now that they have all been fitted onboard Möbius.  First all edges receive their solid Rosewood strips.
IMG_20191227_112029Selim on the Left and Omur clean up and sand the insides of all these Garage interiors and start fitting the doors.
IMG_20191227_112112Each door will have a gas spring cylinder inside so that when you press the locking latch that will be on the lower center of each door, it automatically opens fully and is held there till you push it back and it is locked in the close position. 
IMG_20191227_150123All latches onboard for doors and drawers are high strength positive mechanical latches so they cannot suddenly open in rough seas even if heavy contents inside were to come loose and fall against the doors.

Captain Christine, aka my Beautiful Bride, admires and inspects Ömür’s work on her Galley Garages.
IMG_20191224_170850Back onboard Möbius the window sills along the Stbd/Right hull are now being fitted.  This one is the back of the Settee with the Galley being on the far Right.


IMG_20191224_170859Same area looking along the other Settee back with the Galley and one of the Garages on the far Right.


IMG_20191224_170912One more perspective of the Settee looking at the armrest end that ensures you can’t slide off the Settee down into the steps to the Master Cabin.

As you can see there is voluminous storage everywhere you look.
And that pretty much covers all the progress this last week of 2019!

But WAIT!!!  I promised you more of the preponderance of evidence that Santa is alive and well in Antalya Turkey now didn’t I?  Well, there you go………………..

SANTA’s WORKSHOP:

IMG_20191227_105919First of the many new arrivals at Naval Yachts shipyard this week is this crate apparently full of fragile items.

Any guesses?
IMG_20191227_111410It might be a bit confusing if you remember some of this same gorgeous Turquoise Turkish granite arriving last month but you are correct this is more pieces from that same block.  There were a few problems with the first shipment having some cracks and poor colorations so Yesim contacted the stone quarry and they agreed to send us new replacement pieces.
IMG_20191227_111404You will have to wait a few more weeks to see what these look like installed in the Galley but here is a sneak peek at one piece.
MOBIUS_SALOON_RENDER (4)And this overhead render which Yesim created using a photo of the actual granite to create the surface mapped onto the countertops will give you a bit better sense of how fabulous this will look once installed along with the finished Rosewood cabinetry.
What?  You want more?

IMG_20191227_133426Well OK then.  Mrs. Santa, resplendent in her Vancouver sweatshirt and Starbucks Holiday latte in hand is about to inspect the next pallet full of exciting new equipment, this as you can see being from Webasto.
IMG_20191226_110544This pallet, there are more to come, is filled with the components for the Air Conditioning and Heating system.
This Webasto BlueCool V-50 Chiller at the center of this HVAC Heating Ventilation and Air Conditioning system and will be located out of the way in the Workshop.

This V-50 feeds either cold/chilled or hot water to ……..
…… one or all of the four of these BlueCool A-Series air handlers located in the Cabins and SuperSalon.  There is a 12,000 BTU air handler in the Master Cabin, one in the Guest Cabin and then one 12,00 and one 18,000BTU on either side of the SuperSalon.
We chose this system for its versatility, robustness and quiet.  The Air Handlers are relatively small so they can be easily tucked behind the cabinetry in these living spaces and use ducting to direct the cold or hot air to the different diffusers located within each room.  When the tropical temps and humidity become too high the chiller sends cold water to one or more of the air handlers where it circulates through a radiator with a fan blowing across it cooling the air as it enters the room. 

In colder climes we have two options to keep things nice and toasty inside using this same V-Cool system.  If the air and water temperatures are not too low the chiller can be run in reverse to extract heat energy from the surrounding seawater and use it to heat the fresh water inside the pipes running to each air handler.  With hot  water now flowing through the radiators the exiting hot air warms up the room.

More likely though, if we wanted to use the Chiller to heat the boat’s air we would more likely use the second option which is much more efficient than the reverse cycle method described above and when the seawater temps are below about 10C.  Instead of using the Chiller to extract the heat energy from the seawater, we send some of our DHW Domestic Hot Water to the BlueCool Chiller and circulate this hot water to the air handlers to heat the air in each room.

The Kabola Ecoline Combi KB45 is our primary source of hot water and with a rating of 94% efficiency, low energy consumption and 100% soot free it is eXtremely efficient at heating our water onboard so this will be the most likely source of hot water we would supply the Chiller with.
Isotemp Boiler Basic 75 litersAll our DHW comes from our Webasto/Indel Istotemp Calorifiers which provide us with three ways of heating the 75L / 20USG of water it holds:

  1. Kabola diesel boiler
  2. Gardner engine (when running)
  3. 220V AC heating element


The first two options heat the water in the Calorifier by circulating their hot water through coils of copper tubing inside the Calorifier and the 220V immersion heater heats the water directly with its heating element.  Having these three independent sources to heat our water enables us to chose the most efficient source in any given situation.  Whenever Mr. Gee is running we get to use some of the heat he produces to heat our water for “free” and then when anchored the super efficient Kabola kicks in to keep us with as much hot water as we need for either showering, washing or heating.  On those rare occasions when we are plugged into shore power we can use that typically very cheap and efficient method of heating our water.

When it comes to keeping us all warm and toasty when we are in colder locations however, the coup de grâce will be our in–floor heating system, the beginning of which you have been seeing installed in the past few weeks.  Those of you who have experienced living with in-floor heated homes know that they create THE most comfortable living spaces and we will now have that same luxury aboard Möbius no matter how cold it gets outside.  Stay tuned here for more as Team Möbius gets busy installing all this HVAC equipment.

But wait!  There’s Morrrrrrrrre!!!!!!!!!!!!!!!

IMG_20191228_104842_MPNot content with just the pallet full of Webasto equipment, Mrs. Santa just had to tear into this other new arrival yesterday.  A double pallet full from our favorite US supplier Defender Industries where we get the vast majority of equipment we source from the USA. 


Such as you say?  Well, glad you asked!


IMG_20191228_114131All our Furuno marine electronics and navigation equipment.  I will cover this in MUCH more detail in the coming weeks of 2020 but a short list of our Furuno gear includes:


Furuno FAR-1523 BB Radar

Image result for furuno XN13A"with this XN13A 6ft Open Array antenna

Image result for furuno sc33"Furuno SC-33 satellite compass for eXtremely precise heading information for all our other navigation devices such as ….
Image result for furuno navpilot 711c"our two NavPilot 711C Auto Pilots.  Given the kind of passages we are on Auto Pilot becomes a critical bit of kit so we have two completely independent 711C systems onboard which we can switch between at any time.
Image result for furuno bottmo discriminating"Just as important as knowing what is around us and steering us on safe courses is knowing what is below us and on the bottom of where we are considering anchoring so we also have a bottom discriminating depth sounder


Image result for furuno 220wx"On an even larger scale, we live and sail by the weather so knowing everything we can about weather is also critical information for us and we have this Furuno/Airmar 220WX Weather Station.


In addition to critical weather based information such as wind direction and velocity, air temp, humidity, etc. this solid state (no moving parts) instrument also has a killer 3 axis compass, rate gyro and axis accelerometer which is the technical way of saying it provides us with another source of spot on heading information no matter how much the boat is pitching, rolling and yawing, often through every one of the six degrees of motion!  I put this on our previous sailboat and even up atop a 70+ foot mast the heading data was rock solid which is a huge determining factor in our AutoPilot efficiency and effectiveness.


Image result for furuno UDST800"Lots of other Furuno gear in these boxes which you will be seeing and reading about as they get installed including a very cool ultrasonic water speed transducer which like the 220WX Weather Station above has ZERO moving parts which provides MUCH better longevity and low maintenance.
Some of you fellow passage makers and sailors might be wondering why there is no mention of a Furuno TZT2 MFD Multi Function Device or Chart plotter and that is because we are going with an all PC based navigation system on Möbius.  I will elaborate on all the details of this decision in coming posts and the short version is that we feel this gives us much more flexibility and control over our navigation system and lets us upgrade to things like new graphics cards, processors, added memory and so on. 
Image result for timezero v4"

Our House/Boat computer enables us to do everything and more that a dedicated MFD can with while being more flexible and future proof and with much more bang for our rapidly diminishing bucks!
Captain Christine and son Tim have built a wickedly powerful “boat computer” last month and we brought back with us and have been running here at the house getting it all setup and loaded with software the most important of which might be one of our TimeZero v4 Pro licenses which is what the screen shot above is showing.


Image result for maretron"You might think that Furuno was the only thing that Santa packed into this pallet full of boxes from Defender, but you’d be wrong.  He also included many other equally important bits of kit such as all our many Maretron black boxes and senders which monitor and control most of the systems onboard. 


Our Maretron system, with additional input via our NMEA 2000/N2K network of other equipment, enable us to create custom built screens such as this example above which if you click to enlarge will give you a good idea of some of the systems we monitor, alarms and rules we program such that we know what’s working, how well its working and are alerted immediately when they are not.  While we absolutely LOVE being at sea and seeing the world this way, we need to be  eXtremely well connected to our boat and what’s going on all around us as our lives quite literally and directly depend on this.


BTW, the Maretron N2KView screen shot above is thanks to a pair of our many mentors and favorite teachers out there, James and Jennifer Hamilton aboard their Nordhaven 52 mv Dirona.
If you have not done so previously or it’s been awhile, do spend some time on their awemazing site to learn as we do from all their travels around the world.  A truly mind boggling collection of eXtremely valuable information, learning and adventure.


Image result for standard horizon gx6000"Rounding up just a few more of Santa’s gifts he also brought us some of our many different communications equipment such as this Standard Horizon GX6000 VHF with RAM4 remote microphones along with an integrated AIS Class B receiver.  This amazing device also manages to include a loud hailer with pre-programmed fog signals, GPS compass and DSC Direct Station Calling.

Image result for em-trak A200"Image result for em-trak A200"The Class B AIS receiver in the GX6000 above will be backup to our primary em-Trak Class A transceiver to ensure that we are seen by other ships out there, especially the big guys, and that we are equally able to know they are where they are and can contact them directly at the push of a button.


We had an em-trak AIS and this same multi talented Standard Horizon GX6000 VHF on our last boat and it was rock solid so we are sticking with what we know works and also have its little brother the GX1850G 25W VHF for the Tender. 
Image result for vesper xb6000" We chose this smaller GX1850G VHF above which does not have AIS because on the Tender we wanted a full transponder AIS so we now have a Vesper XB600 which gives us a great AIS to know what other ships are around us when we are out on the Tender and that the Mother Möbius also knows exactly where the Tender is when one of us or guests are out exploring on the Tender.

OK, there was still much more inside all those boxes from Defender but that’s enough to give you a good idea of the bountiful booty which the overly generous Santa brought us and I think meets my promise of showing you a preponderance of evidence that Santa is indeed live and well here in Turkey too!.  Apparently we must have been a VERY VERY good little boy and girl this year, or at least managed to get Santa to think so. 

Both Christine and I hope that all of you were equally good this year and that Santa showered you and your family and friends with a similar excess of evidence of just how good you boys and girls were this year.  My next update will be the end of the first week and month and decade of 2020 so we both want to wish ALL of you the very best New Year and we hope that a year from now you will be able to say that 2020 was one of THE best years yet for you.

Happy New Year from the crew of Möbius and everyone at Naval Yachts.  See you next year!

– Wayne & Christine

Beauteous of Works of Art & Engineering: XPM78-01 Möbius: Progress Update Dec 16-21, 2019

Beauteous of Works of Art & Engineering: XPM78-01 Möbius: Progress Update Dec 16-21, 2019

Say it isn’t so?!!  We’re heading into the last week of the year?  How the heck did THAT happen so fast??

In my naïve youth I used to think that time would slow down as you got older and especially when you “retired” but I’ve never been busier in my life and time has never whizzed by faster.  I think that the reality is that time is one of the few constants in life and doesn’t care how old we are, how busy we are, how much we need to get done, it just ticks away like some rock solid metronome one second at a time.  Back in 2009 I recall a similar year end experience in what was then my second year of single handed sailing around the world in my former sailboat sv Learnativity, where I was recalling all the different experiences I had been through in the past two years and not being able to believe it was possible that ALL that could have happened in just two years.  Drove me crazy for a week as I was sure that somehow my “math” was wrong because it MUST have been more like fife years.  But nope, it was just two.  Over time, hehehe, I came up with the notion of Learning/Living Density or simply Experiential Density and that is perhaps the variable; same amount of seconds in the year, just varying amount of experiences, learning and living for each of us.  Whatever the case 2019 has been a year VERY densely packed full of awemazing experiences and learning for Christine and I and I would hope that is the case for all of you as well.  But enough philosophising and let’s get busy reviewing the density of experiences building Möbius this past week of December 16-21, 2019

STEERING SYTEM:

IMG_20191120_121849As per part of the title there was some eXciting progress with on the Steering related equipment on XPM78-01 this week as well as many other systems and I’ll take you through all of those as well, however steering is perhaps THE most important system on any boat and especially on a power boat and eXceptionally so on an XPM given the eXtremely remote locations we and other eXtreme Passage Maker type boats tend to roam. 
IMG_20191120_121842On a sailboat if you were to lose all your steering such as having your rudder fall off then it is relatively easy to steer the boat using the sails.  Ask me how I know! 
IMG_20191120_121901However with no sails if we were to ever somehow loose ALL steering capability on Möbius about the only option we would have would be to use one or our drogues or other warps you can fashion from long knotted or weighted lines and drag them off the Swim Platform and change the direction of the boat by moving the attachment point from side to side. 
IMG_20191118_105539All that being a VERY Waynewinded way of saying that we take the Steering System on the XPM’s VERY seriously.  Uğur will help give you a better sense of size and scale of the rudder so you can see that it is both eXtremely strong and eXtremely big.

The other photos above show the rudder in various stages of construction and it is now all complete and ready to be installed so let’s go check out this week’s progress.
IMG_20190919_145617These are the pair of self aligning PETP roller bearings which I worked closely with Thor Christen Hermann. the Systems Designer at Jefa Rudder Bearings in Greve Denmark to get them just right.  Thor and everyone at Jefa was fabulous to work with and I can recommend them highly for any of your rudder related needs.


Jeffa rudder bearing Xsection diagram w rudder postIn the photo above the bearing on the left is the top bearing, lower on the right and the white ring in the middle is a thrust bearing to deal with any vertical forces and the black ring is anodized aluminium lock ring that is secured to the Rudder Post with locking setscrews.  This section view from Jefa clearly shows how these bearings are mounted inside the yellow coloured rudder tube which is an integral component welded into the hull’s framing.
IMG_20190919_145652A closer look at the lower bearing lets us see the black rollers for the 127mm/5’” aluminium Rudder post to smoothly glide on and down by my thumb you can see how the white inner race with these rollers inside, rotates inside the white spherical outer race which is fasted into the top and bottom of the Rudder Tube as seen above.

IMG_20191216_102927Next up, the 200mm/8” thick walled aluminium Rudder Tube is tacked in place after being precisely positioned with laser levels such that it is perfectly aligned in all directions and exactly on the centerline of the hull.

Let’s go see where those beautiful tendrils of smoke are coming from?

IMG_20191216_102634Aha!  Now that Uğur and Nihat have tacked the Rudder Tube into position and also tacked on the additional 25mm/1” thick support braces, everything can be fully welded into the hull.
IMG_20191216_154822This is one of the last major welding jobs to be completed and only leaves the installation of the Nogva CPP propeller and shaft to literally float our boat in the sense that she will be fully watertight.

Naval is using the latest Pulse MIG welders and in photos like this one you can actually see the pulses refracting the light which I thought was cool.
IMG_20191216_102705Good comparative shot of the tack welds and the fully finished welds around the circumference of the Rudder Post where it exits out the top of the curved 15mm/ 5/8” plate of the Prop Tunnel.
IMG_20191216_122508That same area now fully welded on the inside ….
IMG_20191216_154700… bottom of the Rudder Tube fully welded on the outside…..
IMG_20191216_154958 … and top of the Rudder Tube fully welded to the Rudder Shelf inside the very aft end of the Workshop area.  Door on the left puts you out on the Swim Platform.
IMG_20191220_104159

Once everything cooled down the Jefa Rudder Bearings could be test fit into the Rudder Tube and we are looking up from under the boat to see the bottom Rudder Bearing here. 


Next step will be to pump a special adhesive through a hole drilled through the side of the Rudder Tube and out a hole in the other side to fill up the special groves in the outer white bearing race and solidly affix the outer bearing to the Rudder Tube.
OK, we’ve got a Rudder, we’ve got a Rudder Tube and Rudder Bearings, but how do we TURN the Rudder?


IMG_20191218_172918Oh right!  The Tiller Arm I designed and has now been fully machined and fresh off the table of the CNC milling machine over at Tasot.  If you’ve been following these weekly progress updates recently you’ll recall seeing this at huge block of aluminium being machined into the finished beauty you see here.
IMG_20191220_115855I walked over to Tasot a few days ago with my rolling cart and brought this work of art and engineering over to Naval to test fit it to the Rudder Post. 

Easy to see how these two halves will be clamped to the top of the Rudder Post with four long M16 bolts running through the four holes in the wings of the body of the Tiller Arm.
IMG_20191220_115926These hardened and precision ground 25mm/1” OD pins are a close sliding fit into the Tiller Arm.
IMG_20191220_115936Providing a super strong axis for the Heim joint ends of the two big Kobelt hydraulic steering cylinders we will see shortly below.  Locking nuts threaded onto the ends of these pins will hold them in place.
IMG_20191220_120741Back at Naval now for the first test fit.  I have implicit trust in 3D models and the precision of CNC machining but we didn’t take the Rudder over to Tasot while the Tiller Arm was being machined so it was a great feeling to set this half onto the Rudder Post and have it fit perfectly!
IMG_20191220_120655And of course the other half fit just right too.

Note the 18mm wide keyway cut into the top of the Rudder Post and in the photo above you can see the matching keyway cut into the Tiller Arm body.


The large through hole at the top of the Rudder Post is also part of the Steering System, the very end of the chain of redundancy and backups.  There is a 70mm/2 3/4” OD thick walled aluminium pipe that is 2m/6.5′ long that can be inserted into this hole in the top of the Rudder Post and be used as an Emergency Steering Tiller. 
At the other end of this Emergency There are attachment points for block and tackle lines to run from the end of this Tiller to the hull frames on each side which would be used to lock the Tiller pipe in any location and move it as needed to steer.  Obviously a bit of kit we hope to never use, though we will test on sea trials, but all part of the “belt and suspenders” approach we take for Steering and throughout the whole boat which enables us to be “Ready for the Unexpected”.

IMG_20191220_121126

Continuing with this “knee bone connected to the thigh bone” and connecting the dots of the Steering System components, we now need to connect the Tiller Arm to the Kobelt hydraulic cylinders and that is what this next bit of Steering beauty is for.  The bronze part in my hand is technically referred to as a Heim joint which is a spherical ball and socket type of joint which transfers the force from the Steering Cylinder to the Tiller Arm.


IMG_20191220_121037Kobelt equipment is eXtremely robust with their two favorite materials being bronze and stainless steel which you will be seeing a LOT of in the coming weeks as we get all the Kobelt equipment installed.  With this Heim joint you can see how it is built to last for thousands of hours at sea with very little maintenance.  A quick squirt of grease in that Zerk fitting to ensure these spherical SS ball and bronze socket are well lubricated and don’t wear is about all that should be needed throughout the long lifetime of these critical joints.
OK, so now the Heim joint connects to ………???


IMG_20191220_121317

This next example of the result when art meets engineering are these Kobelt 76mm/3” ID 7018 Hydraulic Steering Cylinders. 
IMG_20191220_121331The mounting base is where the cylinder is through bolted to thick pads on the Rudder Shelf you saw earlier.  This is another SS/Bronze spherical joint the same as the Heim joint at the other end just encapsulated in this cast bronze base and again a simple Zerk fitting to keep this joint well lubricated, friction free and long lasting.
IMG_20191220_121352And the Heim joint threads onto the other end of the SS shaft Steering Cylinder tom complete the Steering System’s connection to the Tiller Arm.
But wait!  What causes those big beefy hydraulic cylinders to move in and out you might ask, and I’m so glad you did.

IMG_20191219_142422Because I get to show you the final entry into this week’s Art & Engineering Beauty pageant, these Kobelt/Accu-Steer HPU400 Hydraulic Power Units.  The anodized blue assembly on the right end is the very powerful hydraulic pump and the white cylinder under my hand is the 24V motor that drives the pump.  There are two of these two speed pumps, one for each cylinder and we designed these with Kobelt engineers such that one pump and one cylinder exceed the steering requirements under the most severe conditions. 
IMG_20191219_142414Most of the time we will run them this way, one pump/one cylinder and alternate between the two every day or two when we are on multi week passages so we know they are both working and to keep them balanced for wear and use.  If conditions were severe we can chose to run both pumps and both cylinders at the same time for even more power.  In situations such as close quarter maneuvering such as docking in tight spaces, we can switch the pumps to their high speed and cut our 45 degree lock to lock time, 90 degrees total, in half.

Stay tuned for upcoming episodes where we are installing these pumps.


IMG_20191220_115034Some of which Cihan (right) and Okan already got started on this week as well.  They are busy making the two AL shelves to mount the two Accu-Steer HPU400 suspended above the Tiller Arm in the aft end of the Workshop.
IMG_20191220_115045The shelves have flat bar edges so that any spills of hydraulic oil over time are contained and easy to spot as well as easy to clean up.  The three L-bar pieces tacked in place are for the six SS and rubber isolation mounts that secure the HPU pumps in place and keep them running silently.  Next week you’ll see these shelves being mounted.


Whew!  And that only gets us through this week’s work on just the Steering System so let’s move on to the next area of progress; plumbing!


PLUMBING:

IMG_20191218_163822We’ll stay with the multi-talented team of Cihan and Okan as they work on more of their plumbing jobs down in the Basement.  While they were in the fabricating mood and tools they built this support rack for the Potable/Drinking Water tank. 
IMG_20191220_142101This poly tank is another example of the “Readiness for the Unexpected” approach in that it will hold 210L / 55 USG of fresh water that will be kept independent of the rest of the boat’s water tanks and domestic water systems.  It will be plumbed to an independent water pump and connected to a second faucet at the Galley sink.


IMG_20191220_142055The only potable water we allow onboard is what comes out of our 200L/52USG per hour watermaker, never any shore side water so we know the quality of the water is the highest, being essentially pure H2O.  However, there is always the chance, however remote, that the water in the six integral aluminium hull tanks could get contaminated or even more unlikely could escape.  So this tank with its own pump and filtration system will always be at the ready just in case the unexpected should happen.


The white unit on the right is the Vacuum Generator for the Guest Cabin VacuFlush toilet.


IMG_20191218_125119Above the VacuFlush Vacuum Generator is this manifold which controls the hot water flowing to the three zones of the in-floor heating in each Cabin.
IMG_20191217_163239Cihan has done his usual masterful job of installing these manifolds and picking up where we left off last week.  Domestic Hot Water DHW from the IsoTherm Calorifier flows into the red handled shiny SS upper Supply manifold and then out the three fittings with the red flow meters on top. 


Zone 1’s gray PVC/Red handle ball valve is dry fitted in the center to help determine the location of the circulation pump mounts which are the two aluminium L-bar pads on the right.  Zone 2’s pump will mount on the pads you can just see at the bottom right and more fully in the photo below.


IMG_20191217_163231After circulating through the 15mm PEX tubing embedded in the floors in each zone, the slightly cooler water flows into the bottom of the polished SS Return manifold  through the 3 SS threaded fittings below the 3 white flow control valves and returns the water back to the Calorifier via the black insulated PPR pipe with the blue handled SS ball valve.


There is a temperature gauge on both the Supply and Return lines to make it easy to see the temperature differential and performance of the system.  The vertical SS units on the left ends of each manifold are for draining/filling the system and for bleeding off any entrapped air.


IMG_20191216_122827These are the AL brackets which Cihan has come up with for mounting each of the three speed Zone Circulation Pumps to the bulkhead.
IMG_20191218_125142Here is the completed bracket test fitted to one of these pumps.  Longer bolts will be used with an additional nut on each end to keep the clamping of the pump’s sealing flange independent of the mounting nut.  Each one of these pump mounts will be bolted to those pads you saw in the photos above with rubber noise isolation separating the mounting bracket from the pads and keeping noise and vibration locked up in the Basement.


NOGVA CPP PROP & SHAFT

Well, let’s give Cihan and Okan a bit of a rest and move on to the ever busy Aluminium team of Nihat and Uğur.

IMG_20191217_162937After spending the weekend in the freezer to shrink, the orange coloured Cutlass bearing was pressed into the outboard end of the Nogva Prop Log Tube you saw being installed last week.  The groves in the upper half ensure that water flows freely out of the tube and provides a steady supply of clean water to lubricate the prop shaft. 
When rotating the prop shaft “floats” on a thin film of water so that the Cutlass Bearing material and the prop shaft only touch when the prop is not moving.


IMG_20191217_181519That all set the stage for the Nogva CPP Controllable Pitch Propeller to be test fit.  The smaller diameter end of the CPP prop hub at the bottom here is what fits inside the machined AL housing you see in the photo above.  The stepped flange slides in about half way 20mm/3/4” into the AL housing and acts as a rope guard when, never if, you happen to snag a lobster pot, fish net or other underwater debris.
IMG_20191217_181506At the opposite inboard end of the CPP Prop Shaft is the push/pull rod that runs inside the hollow prop shaft all the way from this threaded end to inside the bronze CPP prop hub.  As this rod is moved fore/aft by hydraulic pressure inside the Nogva CPP servo gearbox the bottom end of each of the four prop blades is rotated in synch to change the pitch from zero to full forward or full reverse.
IMG_20191118_102450Okan then gave the whole prop and shaft a thorough cleaning and a small army of men picked up the eXtremely heavy prop/shaft assembly and carefully slid it through the Cutlass Bearing until that stepped bronze end of the prop hub was the correct 20mm inside and attention can now turn to positioning the mounting brackets for the Nogva CPP Servo Gearbox inside the Engine Room and which we will pick up on in next week’s installment.

ALUMINIUM WORK:

IMG_20191216_154850Speaking of the Engine Room, Nihat and Uğur were busy in there as well this week.  With that clue can you guess what they were working on based on this photo?
IMG_20191216_155737Full marks to those of you who guessed Sea Chests!  These are located at the very front end of the Engine Room with the larger Supply Sea Chest on the right and Exit on the left.  There will soon be two Vetus strainers flange mounted to the two pipes coming out of the Supply Sea Chest which will then both feed a sea water supply manifold for consumers such as the Water Maker, Gardner heat exchangers for cooling engine oil and coolant as well as the Nogva heat exchanger and then exiting into the wet exhaust system.


IMG_20191216_155848The 25mm/1” thick Engine/CPP beds are the flat sloped surfaces running top to bottom in this photo, water tanks on either side of them with their respective access ports bolted in place and SAE flanges around them for tank gauge senders and fill/supply lines.  Engine Room diaphragm Bilge Pumps can be seen on either side of the WT Bulkhead with the Guest Cabin/Office on the other side.


IMG_20191216_155803Not easy to get the MIG gun all the way down here but the welder did a great job of getting a full set of deeply penetrating welds around the circumference of this Supply Sea Chest.

WATERTIGHT DOORS:


IMG_20191219_120651Yet another exciting bit of progress was Nihat (left) and Uğur getting started on the frames for all the WT Doors!  They started with this door on the Port/Left side of the Swim Platform that provides access to the HazMat where we can safely store any Hazardous Materials such as diesel, paints, thinners, etc..
IMG_20191219_120701This one door they will build entirely in house here at Naval and the others will be high end WT fully certified WT doors from Bofor. 

Here they are fabricating and tacking in place the inner flanges for the HazMat door frame.
IMG_20191219_143013Which they complete very quickly,
IMG_20191220_141813With the exact sizes of the frame now set, they moved on to fabricating the HazMat door.
IMG_20191220_103140And had that knocked out just as quickly.  Next week they will fabricate and mount the hinges and seals.
IMG_20191220_104935Sliding over to the opposite Stbd/Right side of the Swim Platform they tacked the inner frame flange for the Bofor WT door.  These doors will be bolted in place with industrial adhesive in between to seal completely.

Bofor D0hg_exterior_duzeltilmisBofor is custom building all the WT doors for Möbius to our specifications but will look similar to this one.  To be fully WT certified there will be two dogs/locks at the top/bottom rather than one as you see here and our doors will be left unpainted AL to match the rest of the boat.

The WT off the Aft Deck into the SuperSalon will have a full length window whereas the one on into the Workshop and the one between the Guest Cabin/Workshop will have a single window like the example here.
IMG_20191220_104940With the mounting flange tacked in place, Nihat trims it to final opening size for the Bofor door frame to set into.
IMG_20191220_103945_MPCihan clowning it up to show how the door frame and flange look from inside the Workshop.  The Accu-Steer pumps and Tiller Arm you saw earlier in this post are sitting off to the right of this photo.
IMG_20191220_164221And before you know it the frame flange is fully welded in place and ready to have these corner welds cleaned up and radiused.

CABINETRY WORK:

IMG_20191217_163100More beauty to be found inside of Möbius this week as always.  Omur, Selim and Omer often get to steal the show as their expertise and craftsmanship really shines as they work with the rich grain patterns of the Rosewood.  This corner where the lower Freezer cabinet meets the taller Fridge cabinet is but the latest of many examples of their attention to detail with things such as matching the grain patterns to perfection.
IMG_20191218_125018Stepping back a bit from that same intersection to show how the grain swirls forward onto the wall cabinet for the 50” monitor on the Port side of the SuperSalon and Main Helm.
IMG_20191218_124959A few more steps back to show how the wall has been recessed for that large monitor.  It will be on a HD swiveling mount which allows us to pull it all the way out of the cabinet, swivel it forward and aft and tilt it up down.  This enables us to use this screen for both entertainment viewing of movies and photos from either the Lounge chairs or the Settee for our “dinner and a movie” nights and then quickly reposition it for ideal viewing from the Helm Chair when underway.
IMG_20191218_124830Yet another example of Ömür’s creativity and craftsmanship are these little cut outs so you can easily slide your fingers round the back of the monitor to pull it out.

IMG_20191217_163804Over in the Cabinetry Workshop with his compact sold edge router in hand, Omer shows one of his latest examples of grain matching mastery on this panel that will soon go into the Guest Cabin.
IMG_20191220_141926Back aboard Möbius and down in the Master Cabin, Omur and Selim start a new job of fabricating the laminated Rosewood liners for the insides of each of the ten hatches we designed and built in house.
IMG_20191220_103429They use this special laminating material which as you can see is extremely flexible and can be easily shaped and formed however you wish.
IMG_20191220_142013Solid wood corner blocks are glued in place to provide the backing for the large radius corners of each hatch.
IMG_20191220_164348Then successive thin layers are glued up, let dry and the next layer applied.

We will pick up on this process next week as the laminations continue and then the solid Rosewood edges and veneer goes on to finish these beauties off.

NEW ARRIVALS THIS WEEK:

IMG_20191217_172949The pace of ordering picks up as we get nearer the end of the build so there are more and more new arrivals showing up each week now and here are a few quick examples to leave you with.

Like these four bolts of leather for our interior walls and ceilings!

IMG_20191217_172955One bolt of black leather for the Helm Station surfaces and ceiling above to minimize reflections, one bolt of white leather for the removable ceiling panels and two bolts of this gray/green leather for the upper wall panels.  Can’t wait to see and be able to show you these as they get installed!
IMG_20191221_113340And then five cartons like this one from LiteMax in Taiwan.

Can you guess what’s inside?
IMG_20191221_113152

Yup, our five sunlight readable monitors! 

Two 19” ones side by side at the Main Helm station, two 24” side by side up in the SkyBridge Helm and one 43” on the Starboard/Right side of the Main Helm Chair.


IMG_20191221_113140

I think Captain Christine likes them.  As well she should as she spent months researching and tracking these down.  Our requirements are eXtreme as usual as we need monitors which are:

  1. Full Sunlight readability (1000 nits+) most new smartphones are about 200-280 nits
  2. Dimmable all the way to black for night watches using real front mounted buttons and knobs
  3. Multi-Touch enabled (PCAP)  same as your phone
  4. SXGA resolution 3840 x 2160 or better
  5. Waterproof & Ruggedized

Oh, and affordable too please! 


A tall order to say the least and Christine and I would like to give an eXtremely BIG shout out and thanks to Peter Hayden of mvTanglewood fame for all his help in the early stages of this search as a result of all his efforts in searching for monitors for his previous Nordhaven 62 and now the new N68 he is having built.  Peter had tracked down several of the companies who are the OEM Original Equipment Manufacturers for these kind of high end monitors for the marine industry.  If you are not familiar with Peter’s work on mvTanglewood and his constant flow of expertise on the Trawler Forum, do yourself a favor and go check this out ASAP.  Peter is an endless source of great ideas and expertise and writes outstanding explanations of his work and experiences.   A MUST read for Christine and I and we hope to share an anchorage with our two boats in the not too distant future.

This led us eventually to LiteMax in New Taipei City in Taiwan who make the monitors for airports, railways, stadiums, ATMs and the like and who were willing to make us the Goldilocks just right monitors for us.  It took several months of working with them to get these speced and built and then air freighted to us here in Antalya but they arrived his week and we could not be happier as you can see from my Captain’s face!

They only arrived on Friday and we had a busy Saturday with no time to do anything more than unbox one but we hope to get them setup and tested next week and will bring you more details then.  Just one of the literally thousands of decisions we make and problems we solve every week on this grand adventure of designing and building our just right new boat and home.

Thanks for joining us, please put your comments and questions in the “Join the Discussion” box below and we’ll see you here again next week.

– Wayne & Christine

Let the Chips Fly!!  XPM78-01 Möbius Progress Update Dec. 9-14, 2019

Let the Chips Fly!! XPM78-01 Möbius Progress Update Dec. 9-14, 2019

Another busy week here at Naval Yachts for all of Team Möbius as we ramp up for the final push to launch as early in the new year as possible.  It remains a labour of love for Christine and I but it certainly is all consuming of our time and attention.  This week saw progress in everything from CNC machining the new Tiller Arm now that the Rudder is pretty much finished and ready for installing in the hull to finishing the installation of the prop shaft tube into the hull, plumbing for the in-floor heating system, wiring and of course lots of cabinetry work.  It will take me awhile to get through it all for you so grab a beverage and a comfy seat and let’s go aboard Möbius and check it all out.

TILLER ARM

 IMG_20191209_133245Most of our work with Aluminium to date has been with large plates which are CNC cut to shape and pieced together to form the hull and superstructure.  However as you can see in this photo this hunk of aluminium beauty ain’t no plate! 


IMG_20191209_134155If I tell you that this 152 x 255 x 275mm (6” x 10” x 11”) and 30kg/66lbs block of solid aluminium is just one half of the part, can you guess what this is going to be?


That 150mm/6” long 25.4mm/1” precision ground threaded pin is specially hardened steel to easily withstand the eXtreme forces which can be exerted on it where the Heim Joint ends of the cylinders attach to the Tiller Arm body.  I ordered these and 2 spares from McMaster Carr and brought back with me from our recent trip to Florida.


Tiller Arm bodyA bit of a no brainer given the title of this section I guess!!  A Tiller Arm.

These two quick screen grabs show the design I came up with using Autodesk Fusion 360 which I must say is my all time favorite design and drawing software of all time and in my case that is a LONG time!


You can see how the right side is the second half I mentioned and those four large bolts clamp the Tiller Arm to the 127mm/5” Rudder Post with the 20mm key that goes in the slot on the left side main body.

Tiller Arm w cylinders Turning on some hidden components you can see how the two Kobelt 7080 bi directional hydraulic cylinders with a bore of 76mm/3” ID and stroke of 305mm/12” provide plenty of torque as they push/pull the Tiller Arm which in turn rotates our big rudder up to 45 degrees to each side.


eXcessively massive, time consuming and expensive?  Of course, this is an XPM! and the steering system is arguably the most important system on a passage maker so I’m delighted with such eXcess.


Each cylinder is connected to its own dedicated Kobelt/Accu-Steer HPU400 Hydraulic Power Unit.  Dennis and I worked extensively with the great engineers at Kobelt to come up with this eXtremely robust steering system.  We have designed it such that just one cylinder and one pump significantly exceed the steering requirements to safely steer the boat in even the most severe conditions. 


There will be controls at each Helm station to allow us to select either Steering A or Steering B and our SOP Standard Operating Procedures will be to alternate using A and B for a week or so to ensure both systems are fully operable and being used equally.  At any time for situations such as close quarter maneuvering we can have both pumps and both cylinders working at the same time which cuts our lock to lock rudder time in half.

In the unlikely event that both pumps and cylinders were to fail we then have a Kobelt 7005 manual hydraulic steering pump with wheel at the Main Helm.  And if all of that were to somehow fail we then have an emergency tiller which can manually control the rudder.

tasot_buildingBack to real time photos, the CNC machining is all happening in a building 2 blocks over from Naval Yachts here in the Antalya Free Zone at Tasot Waterjet Cutting Technology
IMG_20191211_154521_MPThey have a small warehouse filled with some of the most advanced metal cutting machines of every description and having the literally next door is one of the great advantages of building here in the Free Zone.

IMG_20191209_133729Here is the whole gang responsible for transforming my design into a very real aluminium Tiller Arm.  From right to left, Yigit our XPM Project Manager,  Hamdi Uysal CNC machinist, Ufuk Bekci Tasot Owner and Tuncay Mutlu Production Engineer


IMG_20191209_133256This is the 5 axis CNC machine in the middle of machining the body of the clamp block.
IMG_20191209_133302Closer view of the Clamp Body with one side finished and ready to be flipped over to machine the other side.
IMG_20191211_153749Hamdi proudly showing the finished Clamp Body.
IMG_20191211_153809IMG_20191211_153803One half done, now on to the Tiller Arm Body.
IMG_20191213_111224With one side of the main Tiller Arm body finished, roughing out the second side begins.  Easy to see why this is called “subtractive manufacturing”.  3D printing is the opposite “additive manufacturing”.
Here is a short little video I’ve put together to show you what this looks like in action.

I was too busy on Friday to get back to see the finished Tiller Arm body so I’ll show you that in next week’s update.


IMG_20191120_121849Meanwhile back at Naval Yachts, the Rudder is all finished and patiently waiting to be installed as Nihat and Uğur ae busy getting the 10mm thick walled 200mm ID Rudder Tube tacked in place as they prepare to insert the finished Rudder. 
Rudder Prop ghosted viewChoosing a few relevant layers in the 3D model and using “ghost” mode this quick render will help you see how the various pars such as Rudder, Prop, steering cylinders and Tiller Arm fit together.  This is in the aft end of the Workshop with the door out to the Swim Platform in the upper left.

.

IMG_20191210_142908In reality mode here is the Rudder Post Tube now tacked in place and just sticking up above the Rudder Shelf.  Same Workshop to Swim Platform door on the upper left.  Next week when the Rudder Post Tube is fully welded in place you’ll see the Rudder post sticking up through this tube with the Jefa self aligning needle bearings top and bottom and the Tiller Arm on top.
IMG_20191210_142945Looking underneath the Rudder Shelf reveals the 25mm/1” thick AL brackets which tie the Rudder Post Tube to the stringers, frames and prop tunnel of the hull and make this all one integral hull assembly.
IMG_20191210_142926Limber Holes or ”Mouse Holes” in the corners where these tube braces will be welded to the hull plates ensures that any water which finds its way in here can easily flow to the lowest point and be removed by the bilge pump and not trapped in these compartments.

PROP SHAFT & LOG MOUNTING

IMG_20191210_102551You may recall from an update a few weeks ago that the machined Aluminium tube, the one with the holes in it here, which the Nogva CPP prop shaft runs inside of, had been fitted into the larger aluminium prop tube that is part of the hull which you can see running up to the top left corner here.

See something new though?

What’s that Orange stuff in that little stubby bit of pipe?
IMG_20191209_173634_MPAnd what might this bit of kit be that is on the floor just below the prop shaft tubes?
IMG_20191209_173935And what are they mixing up here?
IMG_20191209_173919Some of you will recognize this quite universally used Chockfast Orange which is a special 2 part compound which is pumped in fill voids between two parts and rather permanently fasten them together once it hardens.
IMG_20191209_173853After being thoroughly mixed with the hardener the syrupy Chockfast Orange is poured into the red tank you see in the photos above, the lid is bolted down and the tank is filled with compressed air.


IMG_20191209_173910Then a tube connects the bottom of the tank to the filler tube which is temporarily welded to the hole in the top of the hull’s prop shaft tube and the Chockfast flows into the 12mm/ 1/2’” space between the outside of the Nogva Prop Log tube and the larger inside diameter of the Hull’s larger welded in prop tube.
IMG_20191209_174036Up inside the Engine Room, the other end of the prop tubes which have been precisely locked into position with this clamping jig and a tube has been inserted into the pipe that has been temporarily installed where the two tubes have been sealed off to stop the Chockfast from leaking out.
IMG_20191209_174045A few minutes later the Chockfast has filled the entire void between the two tubes and exits out the tube.  Several cupful’s are collected to make sure any entrapped air escapes and then the valve on the Chockfast tank is turned off and we leave this to fully cure in the next 48 hours.  Once fully hardened the two tubes become essentially a single part and provides plenty of space for water to surround the spinning prop shaft at its center. 
IMG_20191213_171521With the Chockfast fully hardened the prop shaft was fitted again to double check the position of this red flange which will soon be bolted to the output flange of the Nogva CPP gearbox.

Where the prop shaft exits the prop log tube there will be a “dripless” seal that fits over the end of the prop tube and seals against the spinning prop shaft to keep all water where it belongs; in the sea and outside the boat! 
IMG_20191213_171525A close up view of the threaded push/pull Pitch rod which runs inside of the prop shaft.  This rod threads into the Nogva gear box and is moved fore and aft by the Pitch Control lever at each Helm.  As the rod moves fore/aft the four prop blades rotate in synch and changes the pitch to anything from neutral, forward or reverse and as more pitch is added the speed of the boat increases.  All a very simple and mechanical system which gives us the ultimate prop, one that is perfectly pitched for any condition.
IMG_20191210_102551At the propeller end of the prop tube, water exits out these holes drilled around the circumference of the machined end of the Nogva prop tube.

Next week the Cutlass Bearing which supports this aft end of the prop shaft will be press fit into place and the CPP prop and shaft assembly can be carefully slid in place for checking of the final fit as we prep for installing the Nogva CPP Servo gearbox.
ELECTRICK GRILL
IMG_20191212_161620One of the many items in that big crate you saw arriving from Florida last week was our Kenyan “Frontier” 220V electric grill that is part of our Outdoor Galley on the Aft Deck.  We no sooner took the box out of the crate than Nihat and Uğur whisked it away and cut in the opening for the grill in the Starboard/Right Vent Box.
IMG_20191212_161620Deciding to go all electric for this BBQ was part of our ability too make Möbius be a single fuel, all diesel boat.  The other big part of this was going with an internal diesel engine in our Tender and I’ll have more for you on all of that in the coming weeks.


All the top surfaces of these two Vent Boxes on the Aft Deck will be countertops, probably using some of the left over turquoise granite from the Galley countertops.  There will be a SS sink in the open space you see here in front of the grill.


IMG_20191212_104050Speaking of electrical, I only managed to catch a few shots of Hilmi and Okan’s progress with some of the wiring this week.  Okan was busy in the Basement prepping these cable trays to be mounted on the ceiling which will be used to support those huge 120 mm2 / 5/0000 AWG red and black cables.

PLUMBING

IMG_20191211_124838Cihan was also a busy boy this past week installing plumbing pieces for several different systems.

He has masterfully crafted these two manifolds for some of the Cold and Hot water systems for moving water from one of the six tanks to another as needed to adjust ballast as fuel is removed and others for getting water from the watermaker you saw last week, to each of these tanks.
IMG_20191211_124851He has done a beautiful job of insulating all of these to increase efficiency of the DHW Domestic Hot Water lines and also keep the Cold water lines from absorbing ambient heat in the Workshop when we are in hotter tropical climates.
IMG_20191213_122907Moving forward to the Basement, more of Cihan’s fine work this week was getting the dedicated Galley Water tank in place.  This is probably more “eXcess” as we can hold as much as 7100L/1875USG of potable fresh water in our six integral tanks in the hull and we have the 190L/hr / 50USG/hr Delfin watermaker.
However as you’ve read previously and often, we always design with our “Readiness for the Unexpected” in mind and this additional 200L/55 USG polypropylene Potable Water tank is one example.  We will treat this similar to the Day Tank for our diesel fuel by keeping it full at all times and it will be plumbed to an independent faucet at the Galley sink.

IMG_20191213_122942Wonder what that shiny item sitting atop the Water tank is?  Yet another bit of kit out of that crate from Florida, this is the manifolds for the three in-floor heating zones.  To my eyes it is a beautiful work of art in its own right and is almost a shame it is down in the Basement where not too many eyes will see it.  The top 3 red towers are flow meters which you adjust with the white knobs on the bottom.
IMG_20191213_171857After some discussion, Yigit, Cihan and I decided this would be the best location for these manifolds, secure against the WT Bulkhead with the Guest Cabin on the other side. 
Supply of hot water enters on the top right and goes out to each of the 3 in-floor zones from the bottom of the Red upper manifold and then returns through the three fittings under the White knobs and back to the Domestic Hot Water system on the bottom right.  Ball valves on all lines coming in and out and temperature gauges on both supply and return so I can monitor the difference.


IMG_20191213_123033Each zone has one of these 3 speed 1/25HP pumps on the supply side to keep the water circulating through the 15mm PEX lines embedded in the floors.
IMG_20191213_123002In the foreground on the left is a Watts mixing valve plumbed into the floor heating water system to help manage the lower temperature water needed for in-floor heating which wants to run between 30-500C/85-1200 F.

In the background is the Azel I-Link three zone Pump Controller which is controlled by individual temperature sensors embedded in each cabin floor.

I’ll have more to show you as Cihan progresses with the installation.

CABINETRY WORK:

IMG_20191209_121805_MPMy Beautiful Bride, aka Captain Christine is at the shipyard most days now and here she is going over the details for the cabinetry and fixtures in this Guest Cabin Head/Bathroom. 
IMG_20191210_172835Standing in the Guest Shower for this shot you can see that Omer has been practicing his cabinetmaking craft very well in this Head.  With the Guest Cabin serving as her Office the majority of the time and with this Head being so close to the SuperSalon entrance and the aft Workshop, it will likely get more use than the Head in our Master Cabin so worth making sure it has the Goldilocks touch of being “just right, just for us”.
IMG_20191211_103715Christine spent a LOT of time searching for this just right sink and finally found one and had it shipped to me in Cannes when I was helping out Naval at the boat show there back in October and I brought it back on the plane with me.

Raised platform in the back is where the VacuFlush toilet will rest at the Goldilocks height.
IMG_20191211_174158Up in the SuperSalon Omur and Selim continue to make great progress.  Here Omur is putting in the perimeter framing for the rigid foam insulation on each stair tread leading down into our Master Cabin.
IMG_20191211_174152All the floors have 40mm/1.6” thick rigid foam board which the 15mm PEX tubing is embedded into and then some of that light weight poplar 10mm marine plywood covers that and the edges of the plywood attach to these epoxy coated solid wood frames.
IMG_20191213_110030Opposite the stairs where Omur and Selim are working you can see how this white framing also provides the perfectly level foundation for all the cabinetry to mount to.
IMG_20191213_171747By week’s end the wall boards were being fitted and will give you, and us, a better sense of how this room will look. 


The large opening on the far right is for a 50” high def monitor which will serve double duty as both our primary entertainment screen for displaying movies, photos, web browsing, etc.  However it is also on a 3 axis mount which enables us to pull it out and rotate it forward where it is perfectly aligned for viewing charts and boat data from the Main Helm chair when underway.

The large vertical openings on the far left will soon house two Vitrifrigo 130L/35USG fridges with doors opening from the center.  The center cabinet is for two of Vitrifrigo’ s band new DRW70  70L/19 USG slide out drawer freezers which can double as fridges with a simple change of their thermostats.

IMG_20191213_110344Over in the Cabinetry Shop I happened to catch Omer as he was gluing up one of the Galley drawers and shot this sequence of shots for those of you who have been asking how the wood “biscuits” I’ve been mentioning work to align and strengthen the glued up wood joints.

You can see 2 biscuits with freshly applied glue on the right….
IMG_20191213_110413One of the drawer sides which has a matching grove for the biscuit is slid in place.
IMG_20191213_110553Same thing for the opposite side.
IMG_20191213_110713Two biscuits and some glue for the final drawer side.
IMG_20191213_110720_MPThanks to the ingenious biscuit power tool which cuts all these grooves everything lines up just right.  The biscuits are made from highly compressed wood fibres so as they soak up the glue they expand and make the joint even tighter and stronger.
IMG_20191213_110317Rinse and Repeat the process and this collection of glued up drawer carcases starts to form.  Once the glue dries plywood drawer bottoms slide into place and are glued and screwed in position to create very stable drawers which slide in and out on their ball bearing self closing slides with just a touch.

POWER!!


IMG_20191209_105220Remember that crate we build and filled with all sorts of parts and equipment that we were sourcing out of the US and arrived last Friday?  Uğur helped me open it up and unpack it all this week.
IMG_20191209_105352Literally hundreds of items inside from Milwaukee cordless tools for me to premium Belgium made pots and pans for Christine and then LOTS of parts for Möbius and they all made it on their flights from Miami to Antalya just fine.
IMG_20191209_115452Two of Möbius’ items whose arrival  we are most excited about are these two bright red beauties from Electrodyne.  I have been working closely with the fabulous people at Electrodyne Inc. for well over a year to have them build these eXtremely heavy duty 250A 24V alternators for us which combined will put out almost 14kW.  So when I say that we don’t have a generator onboard I guess that’s not entirely true?!

** WARNING:  mini Tech Talk Ahead!  Skip over if not interested

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

I’d initially worked with Pete Zinck until he retired early this year and turned things over to his Production Manager Dale Gould and who could not have been more helpful and responsive to my many Emails and requests.

What you are seeing in the photo above are two identical Electrodyne G250-24 models which are de-rated down to 250Amps @ 27.5V @ 3750RPM which would give each one a maximum output of almost 7kW (6.875) for a combined output of almost 14kW.  However I will make the serpentine pulley ratios such that their max speed will be about 3200-3400 RPM for even longer life.  Dale stripped these down for safer, and slightly lighter shipping and I have not had time to mount the HD steel wiring boxes which house all the wire connections you see here for the six large external direct AC output cables which then run over to the external rectifiers and regulators which I will mount outside the Engine Room with thermostatically controlled fans to ensure they are always running nice and cool and at maximum efficiency.  I’ll cover all that in the coming weeks as I get these alternators installed on Mr. Gee our Gardner 6LXB and wired into the electrical system.

I had a list of key features I wanted for our dual XPM alternators running off our single main engine and I knew that it was going to be a challenge to find a company that would build these so with my long past experiences with their alternators I turned to Electrodyne and sure enough they were able to built in all the features I wanted,   In addition to being rock solid, high output and lasting “forever”, perhaps the most significant features that I wanted were that they be brushless and I wanted them to have everything other than the rotating stator to be external.  No built in regulators and no rectifiers.  Why go to such extremes?   In a work; HEAT, which is the largest factor in shortening an alternators output and lifespan. Rectifiers can produce more than half the total heat within an alternator so by removing these and going with industrial grade 3 phase bridge rectifiers I can reduce the internal head of the alternator by more than half AND control the heat of the rectifier bridges outside the ER and with their own fans.   This also creates an alternator with only one moving part, the spinning rotor so MUCH better airflow through the alternator stator windings and rotor.  The Goldilocks alternator for an XPM; consistent high output with low heat and low maintenance. 

I will cover these Electrodyne beauties in much more detail in future posts here once I get them all assembled and installed but suffice it to say that I am VERY excited about getting these Electrodyne alternators installed and tested.  Equally as exciting are the WakeSpeed 500 Advanced Regulators that were also in this same crate of equipment we unpacked this week and will be controlling and managing our two mighty Electrodyne alternators. 

If this stuff interests you as much as it does me then please stay tuned and be sure to subscribe to the blog so you don’t miss any of the new articles as they go live.

OK, now back to our regular programming.

Mr. Gee Gets Naked!

Captain Christine is now working at the Naval Shipyard with me most days now as we make the final push to finish this build and bet Möbius and ourselves back were we belong; ON THE WATER!!

IMG_20191207_141759_MPAmongst her many jobs Christine has literally rolled up her sleeves, donned her HD latex gloves and become Mr. Gee’s personal degreaser!  Our Gardner 6LXB serial # is 196071 which means he emerged out of the Gardner and Sons building in Patricroft in Manchester England in February 1975 and was in constant use powering a tugboat in the Thames river everyday thereafter. 
After 45 years of such use we are giving Mr. Gee a serious bath to start his second life as our main engine in Möbius.  To do so we have removed every single part, nut, bolt and cotter pin and have now removed pretty much every bit of grease and guck that has accumulated over his glorious 45 year past.


IMG_20191207_163006With all the other duties I’ve unexpectedly taken on here along with the regular demands of building a new boat I’ve not been able to get as much time as I had expected to attend to Mr. Gee’s needs but I am contributing more of late and managed to get this massive chrome molly (chromium molybdenum steel) crankshaft all cleaned up and returned to its original shiny self.
20132710_10155688267755572_903598832_oThis is Michael Harrison, the CEO of Gardner Marine Diesel Engines who continues to keep the Gardner name alive and very well.  Michael was also the one who found Mr. Gee for us after a very long search for this completely original unrestored marine version 6LXB.


The Gardner 6LXB, and most Gardner engines for that matter are built with four primary building blocks:

  • Cast Aluminium Oil Pan
  • Cast aluminium Crankcase
  • Cast Iron Cylinder Block with pressed in dry liners
  • Dual cast iron heads

IMG_20191212_110343After one of several strip downs, I had reassembled all these major castings and had the exterior thoroughly sandblasted and then put on several coats of high temp silicone based primer. 

Now stripped down naked once again and ready for the bath of his lifetime, Hakan helped me drag the bare cast aluminium crankcase outside.
IMG_20191211_150746Armed with some super HD degreaser, lots of wire brushes and our newly acquired Bosch pressure washer, it was bath time!
IMG_20191212_110927I had spent the previous 3 days scrubbing every nook and cranny with the degreaser and wire brushes so this final pressure wash took us back down to virgin raw aluminium throughout.  I also wanted to be sure to blast out every oil gallery and hole to remove not only the old grease and grime but also any new particles that had climbed aboard during the sandblasting.
IMG_20191212_125617And here is the result, a VERY clean Mr. Gee!
IMG_20191212_125629This is the front end of the crankcase which will soon be filed with lots of sprockets and an eXtremely large double roller timing chain that drives everything from the camshaft to the PTO for one of those Electrodyne alternators to the water pump and fuel pump.
Whew!!  It is now late on Sunday night and I’m exhausted and so are you probably if you’ve made it this far! 

Thanks so much for joining us, makes this adventure all the more exciting and rewarding to know you’re out there and along for the ride.

Do please add your comments, questions and suggestions in the “Join the Discussion” box below.  Even though I am WOEFULLY behind in responding to those of you who have done so in the past 3 weeks.  Rest assured I DO read them all and think about all you say and I will respond to each one in the next few days so thanks for your patience.

-Wayne

Let the Chips Fly!!  XPM78-01 Möbius Progress Update Dec. 9-14, 2019

Black Water & Clear Glass–XPM78-01 Progress Nov. 25-29, 2019

It has been Thanksgiving week for all our American friends and family back in the USA and while Christine and I are far away and Canadian Thanksgiving was over a month ago, we will take any opportunity to remind ourselves just how many things we have to be thankful for.  Working on XPM78-01 Möbius this past week here at Naval Yachts has been filled with many such reminders that I’ll show you in this Progress Update.  What I am personally most thankful for thought is that my Beautiful Bride and Captain Christine is now finally back in my arms after spending a week in Spain where she was doing some boat and pet sitting for some very dear friends who have their boat enjoying a lovely little marina for the winter in Sant Carles de la Ràpita which is about 3 hours drive SW of Barcelona.

But I”m sure you are much more interested in all those many other things we have to be thankful for this pas week onboard Möbius so let’s go check all those out.

CABINETRY:

I’ll let Cabinetry work take the lead this week for a change which is easy to do given all the progress those two teams made this past week.

IMG_20191128_144921Some of you have been asking how all those mesmerizing swirling grain patterns in the Rosewood are all so beautifully aligned and flow across the different cabinetry components and this shows you one way this is done. 

IMG_20191127_141811Omer has picked out a series of matching slices of Rosewood from the stack you see above, carefully aligned them into this series and temporarily taped them together.
IMG_20191127_142111Next he lays one of the long vertical pieces for the doors and walls in the Guest Shower and Head/Toilet area on top of these strips and uses the edge to guide his razor knife to crosscut the piece of veneer a bit larger than the board it will soon be glued to.  After a short trip to the big heated veneer press, the board is ready for its solid wood edges and further machining.
IMG_20191128_103618In a case such as this piece, the bottom side has Rosewood veneer and the top surface has Beech laminated to them and then the edges and corners are machined with their respective radius, dados/grooves, and rabbets.
IMG_20191128_165843The result? 

This kind of matching grain patterns flowing horizontally across multiple pieces and around corners. 

In case you don’t recognize it, this is the Guest Shower you are looking into with the Guest Cabin to the left and the WT door into the Workshop/ER on the far right.  The shower door itself will be all glass in this case.
IMG_20191125_101506_MPStanding in the Shower and looking across the entryway to the Guest Cabin is another example of the matching grain patterns on this outer wall of the Guest Head in the corridor leading up the stairs to the SuperSalon.
IMG_20191125_101430From the same spot just rotating counter clockwise to Port/Left side of the hull a bit you can see how my “clean workbench” and Office area is shaping up with lots of storage areas above and below the workbench.

Dual Fridge cabinet with more examples of the matching Rosewood is at the top of the stairs.
IMG_20191126_144456This is what you’ll see coming down those stairs from the SuperSalon looking aft into the Workshop/Engine Room with the Workbench/Office along the hull on the right and Shower/Head on the left.  The cut outs in the upper half of each wall are where the padded light gray leather panels will go with the Blue Horizon line and handhold separating the upper leather and the lower Rosewood.
Corridor workbench   StairsThis is a rendered approximation of what this Workbench/Office area will look like when finished.
IMG_20191126_102311For one final perspective I scrambled up the stairs into the SuperSalon and put the camera down on floor level looking Aft to catch this view of the Fridge cabinet on the right and the inside peninsula cabinet of the Galley on the left.  You can see my workbench/Office area in the distant background between the stairs and the Fridge cabinet.
IMG_20191125_102758Next door to the shipyard is Naval’s Cabinetry workshop and over there we find Omur and Selim continuing to make good progress on the smaller cabinets which run along the back edge of all the countertops.  I refer to these as the “Garages”.
MOBIUS_SALOON_RENDER (6)This render looking over the Galley to the Stbd/Right side windows lets you see how these Garages are mounted on top of the rear edges of all the marble countertops.
MOBIUS_SALOON_RENDER (4) - CopyThis bird’s eye view shows how there are four banks of these Garages surrounding the Galley providing a lot of super convenient storage at your fingertips.  Note that the depth of these Garages are all different to provide different amounts of countertop area in front of them and different sizes to each Garage that can be maximized for their contents.
IMG_20191129_125407One of the keys to make these Garages super efficient is to make access super quick and easy and so we have created these “gull wing doors” work like this with the top and front surfaces being made into a single piece that hinges at the back and latches at the bottom.  There are small gas assist cylinders inside so you just lift the latch and the door swing up and out of the way.
I’m quite a car buff and part of the inspiration for this door design comes from one of my all time favorite cars, the 1956 Mercedes Gull Wing 300SL Roadster.  I couldn’t ever afford this model but at one time I had two of the sister 190SL’s I brought back with me from living in Germany in the 80’s.
IMG_20191125_102805My grizzled hand and the spray can provide a sense of scale of this set of Garages which go along the the countertop that runs athwartships/side to side, with the dining settee behind and the Stbd/Right windows on the right end.

IMG_20191128_103514This is the long bank of Garages running along the Stbd/Right side with their back edges up against the window glass.
IMG_20191128_143834_MPSelim putting the solid Rosewood edges on one of the Gull Wing Doors with the bank of Garages in front that run along the windows on the aft end of the Galley.
IMG_20191128_144851Omur has three of the four banks of Garages laid out on this platform as they will be placed in the Galley so he can cut the very complex set of angles for the mitered ends where two banks intersect.  The bank on the floor on the far right fits into the spot where Omur is standing. 
The bottom corner here is where the Aft on the left and Stbd Side windows on the right meet and the short bank of on the right side of the platform is the one with the dining settee behind (to the right) of it.


IMG_20191128_144043Looking from the other side now that Omur has this corner miter roughed in you can see how the bank of Garages will connect to each other.  The short bank on the left is again the one with the settee behind it on the far left side.


Once all these banks of Garages have been fully fitted into the boat they will come back here to have all the Rosewood veneer applied to their outer surfaces and have all their solid edges machined with their radius corners.


PLUMBING:


IMG_20191125_101248Cihan continues his progress with things like getting the Day Tank fitted on the Stbd/Right side of the Engine Room Enclosure so he can now start running all the diesel fuel lines going in and out of this Day Tank.


He has also been running more lines along the sides of the hull such as the Chiller lines wrapped in black EPDM insulation on the bottom here, clear water lines above them and then hot and cold supply lines running up vertically on the far right where they then run across the ceiling over to the other side.

IMG_20191125_101256As each new section of plumbing is installed it is checked for leaks with compressed air and this pressure gauge.  Doing this testing at steps along the installation process is more time consuming but makes it much easier to find any leaks that might show up rather than waiting till the whole circuit is installed and having to track down any leaks along the whole run.
IMG_20191129_155422In the Forepeak up at the other end of the boat Cihan was busy installing the second Black Water (sewage) Holding tank with the VacuFlush Vacuum Generators underneath.


These Dometic BW Holding tanks are a very complete BW Holding Tank system with the diaphragm pump on the right for pumping BW over to the exiting Sea Chest barely visible on the far right end of the tank by the black/red wires and a second independent exit for a shore side pump out connection in the center with the white/green sanitation hose connected.  Well designed with all hoses coming in/out of the top only so there are not any hoses that retain sewage when not being used.  The black cylinder on the far top edge is a vent line filter and the round disc to the right of this is a vacuum release valve which prevents high volume shore side pump out stations from collapsing the tank sides with too high a vacuum inside the tank.  And on the left middle those wires are for three float gauges that connect to green/amber/red lights for empty/mid/full indicators.  We will also install a digital tank level sensor using Maretron submersible pressure sensors that put the precise tank level information onto the NMEA2000 network so we can see and display that data on any monitor throughout the boat or on our phones and tablets.


IMG_20191129_124058These 150L/40 USG holding tanks can weigh up to 160kg/350 lbs so they need to be very well supported and you can see how Cihan has welded in T-bars under the reinforced bottom stringers molded into these Dometic BW tanks.


These T-bars are further strengthened with the AL plate he welded in to mount these two diaphragm low water Bilge pumps.  And the space under the BW holding tank provides a nicely sheltered home for the VacuFlush Vacuum Generator.


WIRING:

IMG_20191126_144200While it may look like Hilmi is laying down on the job he and Okan are actually hard at work putting in this DC junction box for lighting up in the SuperSalon and forward Master Cabin.  This is located on the right side of the stairs going down into the Master Cabin where the 43” monitor will later be installed.
IMG_20191127_141249Just roughed in here but you can already see that Hilmi does very neat and well detailed wiring of all our electrical systems and is now taking full advantage of all those cable trays he installed a few months ago.
IMG_20191129_104022Looking aft from that Junction box you can see one of the many benefits of this design with all this volume running down both sides of the SuperSalon where the side decks run overtop.  These volumes provide unprecedented space that makes installation and future maintenance a breeze as well as providing areas for mounting equipment we want to keep out of the way such as the AC Chiller Air Handlers.
IMG_20191129_123829More of Hilmi’s handiwork is seen here along the Stbd/Right hull in the Master Cabin where he has now installed the four massive Red/Black cables that bring all the 24V DC current up to the Forepeak to run things such as the Bow Thruster, Windlass and Kedging Winch.
IMG_20191129_103948Each of these cables are120 mm2 / 4/0000 to ensure less than 2.5% voltage drop from the batteries.
IMG_20191129_123825For those wondering, these high amperage cables are purposely twisted to help reduce the magnetic fields that are created around each cable whenever current is flowing. 
Fig 7 & 8 Minimizing EMI with twisted cablesThe direction of these circular magnetic fields is in one direction for the red positive cable and the opposite direction for the current flowing the other way in the black negative cables so twisting them slightly like you see here helps cancel the magnetic field out. 

Why do we care? 

Magnetic fields can negatively affect things like compasses and more so interfere with current flowing in other nearby wires so as you can see we also keep these high amp DC cables in their own cable trays mounted as far away from other wires such as AC lines and then we keep data carrying cables even further away and over on the opposite side of the boat wherever possible.

ALUMINIUM WORK:

Uğur and Nihat are relentless in their pursuit of completing more and more of the seemingly endless list of aluminium work to be done and this week was no exception as they finished dialing in the prop tube and started working on the aluminium framing for the glass surrounding the SkyBridge coamings.  Let’s go check it out.

IMG_20191126_101956Using all the measurement tools available from low tech string lines and tape measures to laser levels and dial indicators, the prop tube was brought into full alignment in preparation for being permanently attached to the hull. 

Here Uğur is getting a line representing the centerline of the rudder post precisely positioned so measurements can be taken from that to other parts of the CPP propeller, prop shaft and keel.
IMG_20191126_102048Nihat is sitting directly above Uğur inside the very aft end of the Workshop adjusting the position of this centerline extending down through the hole where the rudder post bearings will mount.
IMG_20191127_105135Using these reference lines they were then able to move the inner Nogva CPP prop log tube with precise and tiny increments by tightening and loosening these four screws to move the tube up/down and left/right until it was in just the right position and then do the same at the other end inside the Engine Room where this tube and the prop shaft enter.


The vertical pipe on top is where the epoxy like ChockFast liquid will be pumped into the space inside between the two tubes and once it is fully filled will be left to harden and lock the whole assembly into one solid component for the prop shaft to run inside.  Now we wait for the ChockFast to arrive for the next stage.


IMG_20191126_130825Next up they started to remount the workbenches and shelves that run the full length of both sides of the Workshop.  Just the lower shelf has been installed on the right to give more room for Cihan to finish plumbing the Day Tank, Chiller pipes and other lines on this side.

But you can see how the Workbench and shelves will look the same on the opposite side.
IMG_20191126_102130Moving up to the WT door leading into the Workshop from the Guest Cabin area to get this shot looking aft to give a better sense of just how much shelf and workbench area these provide.
PH Vent Tunnel under solar panelsThe big new job they started this week though was putting in the AL framing for the clear glass “eyebrow” that runs around all four sides of the SkyBridge.  This raises the height of these partial walls or coamings from about knee level to almost waist level for greater safety but without affecting the 360 degree views when looking out.
IMG_20191127_140534_MPAt the four corners up front there will be tubular supports to both support the forward end of the SkyBridge roof as well as provide frames for the acrylic sheet windows. 
IMG_20191127_161057_MPFirst job was to tack the lower socket portion of these pipes in place atop the flat tops of the front AL coaming.
IMG_20191127_161109The framing for the glass panels which will be glued in place with industrial glass adhesive similar to what is used in building high rise glass sided buildings, is fabricated from L-bar so that was tacked in place next.
IMG_20191129_104146_MPIt is important that the top surface of the glass frames are perfectly level and on the same plane as this will also be the surface that supports the roof when it is lowered down into “cyclone” or “canal” mode and the laser level makes that very easy.
IMG_20191129_104125They are a well oiled team and they quickly worked their way around the whole perimeter tacking the L-bar in place. 

More to follow next week so stay tuned!

  But WAIT!  There’s more!

Several surprise guests showed up and added to the things we have to be thankful for.


IMG_20191129_112516First was this crate which Yigit is busy removing the top from.

Any guesses as to what’s inside????
IMG_20191129_112809Some of you will know immediately when you see this and for those not familiar these three white tubes are the membranes for our watermaker.
IMG_20191129_113703Underneath is this beauty, the heart and soul of the watermaker containing most of the other components such as the high pressure water pump, the pre filters and the gauges for low and high pressure as well as salinity and product water (pure H2O) flow rate.
IMG_20191129_113735Back side has the insulated high pressure lines carrying the seawater into and out of the high pressure pump and you can se one of the filter housings on the left end.
IMG_20191129_113822Not too heavy so quite easy to bring all the components up the stairs and into the Workshop.
IMG_20191129_155225The watermaker will actually go directly opposite of here but as you saw earlier, that workbench isn’t installed yet so we set all the components on this side just to check out the fit on the workbench.


The 3 membrane tubes will mount up on the wall behind the WM and on the far right is the remotely mounted low pressure feed pump which brings sea water out of the Sea Chest into the High Pressure pump. 

Hard to see but the main control station box is wrapped up on the far left side.

I was delighted to be able to source this watermaker from a Turkish Company just north of us as one of my very best friends and fellow liveaboard cruiser had great experience with the watermaker he got from them last year for his boat.  The key thing with Watermakers for me is that ALL the components be “generic” off the shelf items rather than proprietary ones as this makes it so much easier to find replacement parts anywhere in the world as needed over the years.  Fortunately Watermakers have gone this way and everything from pumps to membranes to switches and gauges are all industry standard items that can be found almost anywhere.

For those interested in some of the technical details, this is a Delfin “Maxi 4500” and some of its specs are:

  • Ceramic piston high pressure pump
  • Powder coated aluminium frame
  • 316L SS high pressure control valve
  • 316L SS by-pass valve
  • 316L SS low and high pressure gauge
  • Fresh water flow meter
  • Sea water flow meter
  • Low pressure switch
  • TFC membranes
  • FRP membrane housing
  • 316 SS high pressure fittings
  • 25&5 micron pre-filter
  • Manual fresh water flush
  • Operation time indicator
  • Automatic salinity monitoring and bad product rejection
  • Feed pump

The pumps are all 220V AC and the membranes are standard 2.5” x 40” size which produce 190 L/50 USG per hour.

It was also important to me that our watermaker be all manual rather than all automated.  We are eXtremely dependent upon our watermaker for both potable/drinking water as well as all our domestic water and water we will need to produce during passages to use as ballast to replace the weight of the fuel as it is used.  This added to the challenge of finding the just right watermaker because the trend has long been to make these more and more fully automated where you just “set it and forget it”.  No thanks, I’d much rather start up and shut down our watermaker each time so I know for sure how it is working and can adjust it for optimum output and operation as sea temperature and salinity change and require different settings.

But WAIT!  There’s still MORE!

Hilmi, our electrical whiz, came and asked me to come off the boat with him to check out the new pallet of equipment that had just arrived.

IMG_20191129_160516Which turned out to be THIS pallet full of beautiful blue Victron boxes!

I will go over this in MUCH more detail in the coming weeks but at the risk of causing some serious drooling by some of you, I’ll just leave you with the following photos of what’s inside some of these boxes………….
IMG_20191129_164406IMG_20191129_164415IMG_20191129_164612IMG_20191129_164658IMG_20191129_164706IMG_20191129_164714IMG_20191129_164754

And so that’s the week that was Nov. 25 to 29, 2019 here on Project Goldilocks with Team Möbius.

Thanks SO much for taking the time to join us and PLEASE be encouraged to put your questions and suggestions into the “Join the Discussion” box below.

-Wayne

Let the Chips Fly!!  XPM78-01 Möbius Progress Update Dec. 9-14, 2019

Go BIG and Go Home! XPM78-01 Möbius Progress Update Nov. 18-22, 2019

Finally catching up with some of the backlog after my 3 week trip back to Florida, BC and California and able to bring you up to date as of Nov. 22nd, 2019 on the continued progress in building our XPM78-01 eXtreme eXpedition Passage Maker aka Möbius at Naval Yachts here in the Antalya Free Zone in south central Turkey.

Lots to show you find a comfy seat and a good beverage and let’s take a tour through all the work Team Möbius accomplished during the week of Nov. 18-22, 2019

RUDDER:

By far the most exciting work this past week has been the test fitting of the Rudder and the CPP or Controllable Pitch Propeller system.

IMG_20191118_102357Contrary to the popular saying “Go Big or go home” we’ve decided to do both with this beautiful big prop that will take us to wherever we want home to be that day.  Four blades as you can see with an OD of 1m/40”.


Show is always better than tell so check out this quick little video with Uğur showing how the pitch changes as the four blades rotate in unison.

I will cover the CPP system in much more detail in the coming weeks but it is a very simple system and one that is used in workboats worldwide for decades although not something that is too well known in the North American and recreational boating markets for some reason.  As you see in the video the blades can pivot on their bases inside the hub and this rotation is caused by a simple small diameter 12mm/ 1/2” push/pull rod that moves fore and aft sliding inside the prop shaft.  This push/pull rod extends out of the prop shaft inside the boat and is threaded into the center of the flange on the CPP servo gear box which uses hydraulic pressure to push/pull the rod as you move a simple lever in the Helm station.

Why you might ask?  Well, simple explanation for now, from your equally simple author, is that a fixed pitch prop which is what most of us would be most familiar with, is pitched to be just right at one RPM and one set of conditions.  At this point the prop is at maximum efficiency and is probably a little bit more efficient than an equivalent CPP system.  BUT, at any other speed of the boat or the prop and in any other conditions, the CPP can change the pitch to be just right all the time.  This allows us to dial in the perfect pitch and hence perfect engine loading and fuel burn at any speed we want to maintain in most any conditions.  Maximum efficiency translates directly into maximum fuel economy and maximum engine life so you can start to understand the appeal and why we went this route.  And without getting into the details, contrary to what most would think and I did too initially, if you are building a new boat the cost of a CPP vs a fixed pitch prop is about the same.

One last fun fact for you about our CPP system is that the gearbox is also simplified because it is only providing the 3:1 gear reduction and there is no need for any forward/reverse gearing or shifting.  Huh???  Say what???

Simple really, while there is a clutch that we can switch on/off to engage/disengage the engine from the prop shaft, most of the time we don’t bother.  Instead, the prop is spinning pretty much anytime the engine is running and neutral is established by setting the pitch to zero.  Think a knife on edge cutting through the water.  When you want to move forward you move the CPP Pitch lever in the Helm forward and the pitch now changes as the lever moves the push/pull rod and the boat moves forward.  The further you push the Pitch lever the faster the boat moves as the thrust builds with the increased pitch.  Pull the lever back to the straight up and down (typical) position just as you would do on a traditional throttle lever and you are back at neutral.  Continue to pull the lever back and the boat moves aft.

This gentle feathering of moving forward and aft rather than the “clunk” of shifting between Neutral/Fwd/Reverse on a traditional transmission and fixed prop adds to both the ease of close quarter maneuvering and the life of the propulsion system.   As you can tell we are REALLY looking forward to trying out CPP system out once we launch and we’ll bring you along for those rides too.  Now, back to work

IMG_20191118_105539Appropriately pleased with himself Uğur now has the partly finished rudder slid into place inside the hull and set into its position so we can double check all the many dimensions that are part of getting the overall propulsion and steering systems just right.
IMG_20191118_105653_MPThis is the first CPP system Nihat or Uğur have installed, (mine too!) so it was a very fun experience getting all these components test fitted in place.
IMG_20191118_110013This is what things look like On the other end of the prop shaft inside the Engine Room.  You can now clearly see that threaded push/pull rod as it exits the 65mm/ 2.6” diameter prop shaft.  Changing the pitch is as simple as moving this rod forward and aft.
IMG_20191122_150441Once we had assured ourselves that all the dimensions and clearances were spot on, the CPP prop and shaft assembly were slid out and set aside for the next big operation which is affixing the CPP prop log perfectly centered within the prop shaft tube of the hull.

It might look like a crime scene but the tape is just there to prevent anyone from walking into or disturbing the lines and lasers used to set and align these two tubes concentric with each other.


IMG_20191122_123436The large machined cylindrical end with the holes in it is the aft end of the Nogva supplied prop log tube which then extends about 2m/7ft up inside the outer prop tube welded into the hull.  The goal now is to get these two tubes perfectly aligned with each other and then a special epoxy liquid will be pumped into that vertical pipe you see here and fill up all the space between the two tubes. 
Once hardened the two tubes become one and we only get one chance at this so we are taking time to check everything multiple times and get everything lined up before pumping the ChockFast into the void inside.


IMG_20191122_122619At the other end inside the Engine Room, Uğur has tacked in place this aluminium ring and using four short bolts, similar as to what you see in the photo above, these screws are turned to bear against the inside prop log tube and move it up/down/left/right to position it just right.


The clear tube taped to the bulkhead is where the ChockFast will exit the inner void as it is pumped all the way up and we’ll know that the whole space is filled and can be left to harden.


IMG_20191122_123423This close up shot lets you see all the way through the machined Nogva prop log tube to the Engine Room.
IMG_20191122_120446There are a lot of interrelated dimensions and measurements we need to take to ensure that not only is the prop shaft properly aligned within the tubes but that it is also alighted with the center of the Rudder Shaft and that the CPP prop is also aligned with and spaced away from the leading edge of the Rudder blade and the trailing edge of the of the Skeg plate. 


Here, Yusef is double checking the line marking the center of the prop shaft with the vertical centerline of the Rudder shaft, both of which have been set and checked using the ubiquitous laser level.


Be sure to stay tuned to this channel for next week’s episode of “As the Prop Turns”.

PLUMBING:

IMG_20191118_102601I covered much of Cihan’s work on the plumbing in the previous weekly update but here we find him installing all the valves on the diesel Day Tank.  The Day Tank is on its side here with the bottom facing us and you can see the round sump that has been welded in to provide an out of the way spot for any water or dirt to accumulate and then be easily checked and drawn off into a small container by opening the ball valve.
IMG_20191118_102731The other ball valve near the middle here is the main take off for both our two diesel consumers; Mr. Gee our might Gardner 6LXB main engine and our Kabola diesel fired water heater.

The elbow at the top will feed a sight tube that goes up this outside corner of the tank and gives us an always accurate, always there fuel gauge.


Cihan is attaching the bottom access port for annual inspections and cleanouts if needed.


IMG_20191118_103036Completing out Day Tank tour today up on top we find three valves controlling the input and outputs to the tank and the bosses on the far right for fuel gauges, one a submersible Maretron pressure sender and the other a mechanical Tank Tender type gauge.

CABINETRY WORK:

I was particularly delighted this week to see more progress on “my” Office and “Clean Workbench” space. 

Corridor Head Shower Guest Cabin Layout labelledFor orientation, this cutaway rendering shows the layout of the Aft Cabin on the right, Head & Shower to the Left and then my workbench and office space on the far Left up against the Port hull.


The Corridor connects the stairs coming down from the SuperSalon and takes you to either the Guest Cabin on the left or straight through the WT door into the Workshop and Engine Room.


Corridor workbench   StairsThis more realistic rendering, with the Guest Shower removed for clarity, shows what a great little office this will be for me or others to take advantage of.
IMG_20191118_103224And here is what the real thing is looking like so far.  Overhead storage cupboards, plenty of drawers under the workbench and a large opening in the center for the swivel out chair.  WT door into the Workshop/Engine Room is on the left.
IMG_20191118_103217Swiveling to the right to show the forward end of this Corridor area, the wall for the Head is not yet in place so you can see the large cupboards flanking the stairs as they wind up to the SuperSalon level.  These two cabinets alongside the stairs will be primarily AC and DC electrical distribution panels with switches, circuit breakers and such for the aft area of the boat.
IMG_20191120_122715Stepping just inside the WT Door into the Workshop/ER area and looking forward gives a good sense of just how large the Port side Office area is going to be. 

Not that I am at all excited about this.
IMG_20191118_103541On my way up those stairs to the SuperSalon as I came to the new cabinet for the 2 Fridges, I just had to try out these super cool, not that I’m biased, hand holds that run throughout the whole interior and will have an illuminated “Blue Horizon Line” on the inside surface.
IMG_20191118_103626_MPStanding in the Galley looking across to the Port/Left side you can see how this Fridge cabinet begins where the stairs end and then transform nicely into the two drawer Freezers that are tucked into the big space under the side decks of the hull.


This was partly inspired by one of our dear friends, Sue, when she commented a while back that she really liked the whole SuperSalon layout but wanted to know where she would be able to put her Martini glass when in the lounge chairs that sit on the far right area in this photo???

The top of the Freezer cabinet is your answer Sue and we can’t wait for you to come try it out in person.


IMG_20191118_104322I haven’t hand time to do any video tours lately so until I do, I’ll spin around the SuperSalon with some still shots to give you a better sense of the overall layout and relative sizes.

Standing in the forward Starboard/Right corner of the SS looking aft and to Port provides this view of the Freezers on the right, Fridges and under drawers on the left and then the stairs up to the Aft Deck or down to the Guest Cabin.  Corner of the Dining Settee in the bottom left.
IMG_20191118_104330Moving over to the middle of the SS about where the Helm chair will be lets us look directly aft and see how the whole Dinning area, Galley and Fridge/Freezer cabinets look.  Now imagine this with sparkling blue tropical waters and some palm trees on the nearby uninhabited island visible out all that 360 degrees of glass.

IMG_20191118_104335Standing in the same spot but looking over to the Stbd/Right side a bit gives a sense of how spacious the Dining Settee will be.  Stairs leading down to the Master Cabin on the far left.
IMG_20191118_110845Continuing to swivel left and now looking forward this is an early mock-up of the Main Helm area and you can see through to the Master Cabin below.  The blue is rigid foam insulation ready to be routed for the PEX heated flooring tubing to go in.
IMG_20191122_123254Moving Aft and climbing up the stairs to the Aft Deck lets me give you this slightly aerial view of the whole SuperSalon.  As I hope you may be starting to see, calling this the Super Salon was an obvious call.
IMG_20191122_113637Now let’s take a walk over to the Cabinetry Shop to catch up with the team over there and see what they’ve been working on this week.

Yeşim and Ömer are discussing details of this latest example of the gorgeous grain of the Rosewood.  Can you guess where this panel will go?
Entry to Guest Cabin Head ShowerFull marks to all of you who guessed this wall on the inside of the Corridor we were looking at earlier opposite my Office/Workbench.  Entrance into the Guest Cabin in the center with the Head on the left and Shower on the right and then the WT door leading into the Workshop/ER on the far right.
IMG_20191122_113717Here is that wall panel now right side up as Ömer shows us how he proposes to create the corner door frame for one of our “Swiss Doors” which close into a door jamb on both sides.  In this case this one door can close in the Head or the whole entrance into the Guest Cabin.
IMG_20191122_114003Close up of two parts of the glued up door jambs ready for machining and laminating.
IMG_20191122_115638Over on the other side of the shop, we stop to discuss the above countertop storage which we refer to as the “Galley Garages”, with Ömür on the left, Yeşim middle and Selim.
MOBIUS_SALOON_RENDER (1)This render of the Galley in the upper left area will give you a better visual idea of what these Galley Garages will look like and how much storage space they will provide.  With 360 degree glass we don’t have any cupboards above countertop height so this was a way to have both lots of storage in the Galley and maintain those great views all around.
IMG_20191122_115645_MPThis is the prototype that Ömür has whipped up and we are going over with him.  The doors to the Galley Garages are a single piece made by joining the top surface and the angled surface you see here together into one piece.  The hinges go on the back side and there are small gas assist cylinders inside so as soon as you press the latch the doors swim up out of your way letting you see and reach all the way to the back without bending over.


You will soon see how this all works next week as Omur and team build these cabinets so stay tuned.


IMG_20191122_113526I’ll finish for this week with one last bit of Ömür’s craftsmanship, these beautifully executed grills which will be all around the SuperSalon directing the ventilation air, both hot and cold, into the room along the windows.  This is a quick prototype Omur put together for us to test out with air flow and looks.  We think we will make the final ones a bit wider and narrow the slats to increase the air flow and reduce the noise of the air flowing through them.

What do you think?

OK, that gets you up to date as of Nov. 22nd, 2019 with where we are at on the Good Ship Möbius.  Thanks for your patience in me getting these last two updates posted.  I don’t have any travel plans other than traveling off on Möbius early in the new year so I should be able to get back to timely weekly updates.

Great to have you along for the ride and please send in any and all questions, comments or suggestions in the “Join the Discussion” box below.

Thanks!

-Wayne