I double checked the calendar and it is indeed just the beginning of May but it sure feels like summer here in Antalya today. We’ve been having fabulous weather all year actually with an eXtremely mild Winter season that saw very little rain and very mild temperatures. But Spring has been off the charts in terns of great temperatures, low humidity and no rain. Today, Sunday May 9th, is a real scorcher and as I sit and type this aboard Möbius at 14:00 the temperature is a toasty 34C / 93F with a little bit of wind and crystal clear skies. No complaints from any of the crew aboard the good ship Möbius, that’s for sure.
While the lack of visual progress to show you continues as we work our way through the final jobs remaining to fully configure and test all the many systems onboard XPM78-01 Möbius, the amount of work required to play this real world version of Whack-A-Mole is relentless and non stop. That combination conspired to prevent me from putting together an update for you last week and I thank all of you who wrote to ask if all was well and thank all of you for your patience. In this Progress Update I’m going to combine the past 2 weeks into this one, so please grab a comfy chair and beverage and join me for a Show & Tell of what’s been happening from April 26th through May 5th, 2021.
All Hands on Deck!
In addition to all the configuration and testing, there is also a long list of those “little jobs” that add up to be quite a large amount of work all together and we knocked off more of these the past 2 weeks as well and here are a few examples.
Here we find Captain Christine, ably abetted by our two four legged crewmembers, Barney (Left) and Ruby, finished whipping the Dyneema lifelines she had previously spliced in place and which are working out eXtremely well. The Rosewood Dinette table came back from being refinished and is once again mounted to the vertically adjustable pedestal with the XY sliders that allow us to move the table 200mm / 8” fore/aft and side to side which enables us to always have the table in its Goldilocks position for any situation. There had been some small depressions on the top surface of the table which while minor, were also very visible and took away from the otherwise superb finish on all the woodwork so the Finishing crew quickly refinished it and as you can see it is now flawless. There are a LOT of valves, circuit breakers, hoses, electrical connections, etc. that number in the hundreds and so labeling everything is a must and makes it easy to know what’s what and how to operate all these systems. These 3 fuel manifolds provide a good example. You may recall a few weeks ago that the two cleats on the Swim Step were upgraded from AL pipe to solid and the heat from welding those in required that the TreadMaster be removed and now it has been replaced. The light Grey TreadMaster is also proving to be as good or better than we had hoped. The top priority is to provide a great non-skid surface in any conditions and the tight sharp diamond pattern of the TreadMaster eXcels in this department and locks even bare wet feet in place everywhere. Second priority is to provide a more bare feet friendly surface especially when in hot sunny climates so that you don’t have to do your “walking over red hot coals” fire dance when you are on deck. While not comparable to the tropics, today’s high temperatures and intense direct overhead sunlight gives us a reasonable test and we are happy with the results.
For a baseline, as of a few minutes ago, 14:30 Sunday May 9th, here is the temperature on the fully shaded Aft Deck area which my trusty IR temperature gun clocked at 32.4C / 90F. And out on the Stbd side decks that have been getting the most direct sun right now, the TreadMaster is at about 50.5C / 122.9F. Definately not cold, but I can stand in place on these decks without too much discomfort and when walking it is quite comfortable. As in life, everything is relative right and compared to our previous boats, with painted on non-skid on both fiberglass and steel decks, this is a HUGE improvement, so we’re happy with these results.
Love Thy Dock Neighbor!
You’ve seen in previous postings that we have some very interesting and varied dock neighbors here in the Antalya Free Zone with over 30 different boat builders producing a wild and wide range of boat sizes and purposes. Most of these boats are in a similar situation as we are, brand new being launched for the first time so that all the in-the-water testing and finishing can be done. Then once finished, they are off to their new home bases scattered around the world so boats are leaving and new ones arriving on almost a daily basis. Here are some recent examples of our recent neighbors:
On our Port side we have this 34m/112ft steel “Phi Phantom”. This is a support boat for a much larger superyacht so this is all function with huge flat decks and even larger bays below with that monster articulated crane to get all the “toys” off/on this boat and the superyacht. They also carry all the fuel, supplies, parts and maintenance crew. These kinds of support boats are often called “over the horizon tenders” as that’s where they are to stay out of sight of the high paying passengers on the superyacht or a “phantom boat” such as this one that is to stay similarly ghost like or invisible to the superyacht it supports. On our Starboard side we have this Bering 77 I showed you a bit in my last posting.
At 77 feet long overall, she is 1 ft shorter than Möbius but otherwise MUCH larger at more than twice our weight, much taller, much wider and quite a bit slower than Möbius (8 kts vs 11) but still a Goldilocks boat for the right owner and use case. Down the dock a few more meters is this little fella who showed up last week and is the basis of my “Love thy neighbor” heading for this section.
Why you ask? Look a little closer at some of her deck hardware ……….. Like here for example. Or zoom in a bit closer to read that red safety lock….. The more you look, the more interesting it gets. For example, when those hatches in front of the two rocket launchers are opened up it reveals a relatively typical set of instruments, controls and a small bench seat for the operator. Most of the time though and during testing, these hatches remain tightly closed and fully waterproof. So how do they operate the boat now and where is the Captain sitting? Inside here! Turns out this is a fully autonomous vessel or unmanned drone and the real “Captain” is actually sitting ……. …… here!
“ULAQ” is the first indigenous armed unmanned surface vessel (AUSV) developed in Turkey. It is being offered by Ares Shipyard and Meteksan Defence Systems to the Turkish Navy and you can read all about this fascinating research project HERE and HERE if you’d like to know more details. Suffice it to say that we treat all our dock mates with great respect and kindness!
Get the Lead Out no IN!
This was one of the more interesting things happening with our Bering 77 dock mates this past week.
Can you guess what they are up to and what’s in all those wood crates up on the dock? Is this a Turkish version of a Swill Alps horn? Nope, just an ingenious way of putting the lead ballast into the stern compartments of the Bering 77. Here is what is inside all those crates, 1000 Kg of 5mm diameter lead balls like this. One scoop at a time the little lead balls are poured into this funnel, run down the long black PVC pipe into the holds in the aft end and are then capped off with an aluminium plate that is bolted down overtop.
However, hands down, THE most exciting and interesting thing that happened on the docks this past week happened to us and Möbius.
Hmmmm, what do you think that crane truck is doing behind us?
And what is Captain Christine busy with and what are those weird shaped teak blocks on the Aft Deck? Aha! That’s our Tender flying through the air! and about to be lowered onto those Teak chocks on the Aft Deck. Like this……… ……. and this. And she fits like the proverbial glove and just as I had laid out in the 3D models; with the front Stbd fender just able to rub up against the vertical support bar coming up out of the Port Vent box…….. ……… and the Aft Port corner of the fender right up against the doghouse over the stairs from the Swim Platform into the Workshop. And there she is! Our Tender finally setting in her new home and Möbius is now fully equipped. Sinan, our upholstery master made this tight fitting cover out of some waterproof Sunbrella fabric we had brought over from the US.
This shot provides a good perspective of how nicely everything fits and works together on the Aft Deck with the Tender onboard. Plenty of room in the Outside Galley and the entire Stbd side to walk back and forth the whole length of the boat. Here’s what it all looks like viewed looking forward. Next up is fitting all the rigging to raise/lower the Davit Arch and the Tender within it but that should be a relatively straightforward job that can wait for now.
Oh, and we’ve settled on a name for Möbius’ new “baby” and she will be called “Mobli”. A lot of different parts to the story behind this including a reference to Mowgli in Kipling’s Jungle Book as well as being our sense that Mogli is the diminutive version of Möbius.
Welcome to our family Mogli! We can’t wait to start playing with you in the water and showing you the awemazing aquatic world that surrounds us. Hope you enjoyed this combined 2 weeks worth of Show & Tell from all of us here on Team Möbius. We’ll be back with more next week as we inch closer and closer to leaving the Free Zone and returning to our lives sailing the world.
Starting with the biggest news first; Christine and I took a much needed “mental health day” by renting a car and driving up the coast for an overnight getaway in a lovely little area we’ve been to before that is only an hour’s drive from our apartment in Antalya. We’ve been working non-stop seven days a week for the past six months and thought it would be smart to take a brief break from boat building.
We are very fortunate that the Antalya Free Zone and our apartment are at the very far West end of the city of Antalya that stretches over 30km along the long crescent shaped coastline of the Gulf of Antalya you see here. The mountains rise up around us less than 1km from the beach and we only drive about 2km SW to put us on a fabulous coastal road along the tree lined rocky coast.
Christine found a fabulous little cabin for our getaway in a little village which in the 60’s and 70’s was the center of an area filed with “hippies” from around the world who built a lot of treehouses which have now evolved into little resorts with 2-10 small cabins on the property. So I left the shipyard very early Friday afternoon at 15:30 and we packed up the pups and some snacks and were on the coastal road by four. We checked into our little cabin and then spent a few hours walking through the small village along the river front which filled with lots of arts and crafts shops, cafes and restaurants which led us down to the pebbly beach where our boat dogs Ruby & Barney enjoyed being back to salt water beaches after almost three years of being dirt dwellers with us.
As you can see in the photo above, the beaches are as usual jam packed with other people.
The little “resort” we were at was run by a lovely Turkish family who cooked up a fabulous dinner that evening in an open air patio where we were almost the only guests to enjoy the owners excellent selection of jazz music during our long and leisurely dinner. Our host family again delighted us with a classic Turkish breakfast the next morning and we spent the rest of the day driving along the coast and up into the mountains to explore everything from Lycian tombs (click photo on left to enlarge) to mountaintop Roman ruins complete with amphitheatre and acropolis. We treated ourselves to dinner at our local marina which is only a few blocks from our apartment and the whole experience felt like much more than just an overnight getaway that really helped recharge our batteries for the final push to finish Möbius and Launch!
Back at Naval Yachts, it was another week of disappointedly limited progress on XPM78-01 Möbius herself as their other boat projects seem to take precedence. The bright spot though was that our dynamic duo of Uğur and Nihat make a LOT of progress on the Davit Arch as they finished welding the Davit Arch onto the Aft Deck and it is now ready for rigging.
In the Master Cabin, Serkan continued his single handed work installing the last of our favorite SS latches and he and Sinan completed installing the leather covered panels on the upper cabinet doors and the Bureau of Drawers. Out on the Aft Deck, with Uğur welding the Davit bases to the deck, Nihat turned his attention to installing the EPDM foam insulation in the overhead roof and the big ER Deck Hatch.
So grab a comfy chair and a favorite beverage and join me for this week’s Show & Tell Progress Update aboard XPM78-01 Möbius.
Might as well start with the star of this week’s Show & Tell; the Davit Arch!
Retrieving any dinghy in rough weather can often be eXtremely dangerous so we have been working since the early design stages with Dennis over three years ago now, to design a Davit system that is as safe and as fast as possible.
Christine and I hope that our fellow cruisers who have launched and retrieved their share of dinghy’s and tenders will weigh in with your thoughts on this system by adding your comments and questions in the “Join the Discussion” box at the end of the blog.
First a couple of quick renders to show how we’ve designed this somewhat unique launch/retrieval system for the jet drive Tender to Möbius which you’ve seen being built in the previous weeks.
We had a very good hinged Davit system I had designed for the aft end of our previous sailboat that worked extremely well to launch and retrieve our 4m/13’ aluminium bottom RIB in under a minute so we took all the lessons learned there and used them to help guide us in the much more greater challenge of having a similarly safe and fast Davit system for our now 5m / 16/5’ 1100Kg/2400lb aluminium inboard diesel jet drive Tender. Right now Möbius is sitting too close to the boat next to it inside the shipyard to be able to do a dry run lifting the Tender On/Off the boat so we will have to wait until we launch to find out in real world terms how well this design is going to work. However, between the two of us, Christine and I have cruised for many decades now and have launched and retrieved dinghy’s thousands of times spanning the full spectrum of different sizes and types of dinghy’s and tenders using an equally wide range of davits and we think this Davit Arch system will prove to be the safest and easiest to use Davit system we have ever used. Stay tuned for that real world testing report in the next few months.
As you can see we have used the same type of “ladder” construction for the Davit Arch as on the Main Arch as this style has proven to be a Goldilocks combination of strength to weight and we also really like the overall visual esthetic of this matching pair of arches and how well it fits in wtih the overall eXpedition look of XPM78-01 Möbius. I updated the design just before we ordered the aluminium to make the arch a three piece assembly that bolts together very simply using two doubler plates (light blue in the model) at the transition between the vertical legs and the horizontal beam. This allows us to dismantle the arch and take it down completely either in what we refer to as “Hunkered Down” mode in preparation for an impending cyclone (ask us how we know!) or for “Canal Mode” when we want to eXplore inland canal systems found throughout the world that have bridges with height restrictions lower than our air draft with the Main Arch and Skybridge roof and Davit Arch up. Raising/lowering the Tender will be a very simple two stage operation and I will explain this all in much more detail wtih photos in a future Weekly Update when we start doing the two sets of rigging.
1. One set of rigging will move the angle of the Davit Arch itself from the near vertical Cyan coloured position you see in the first render above that puts the Tender fully up on deck and then lets the Davit Arch move sideways towards the Port/Left side until it reaches the Purple coloured position where the Tender is now clear of the Deck.
This rigging will be an all Dyneema setup starting with two attachment points at the Forward/Aft end of the overhead beam connecting to a a single line extending over and down through a turning block straight across the Deck on the Starboard/Right side Rub Rail and then lead to the big EST 65 Lewmar electric winch in the middle of the Aft Deck.
2. The second rigging will be a double set of vertical hanging lines to raise/lower the Tender in the Davit. When the Tender is up on Deck these will raise/lower the Tender from its chocks and when over the side it will raise/lower the Tender from the water. This will also use Dyneema line attached to a bridal clipped to four attachment points inside the hull of the Tender leading up to a block and tackle handing down from the Front and Aft ends of the overhead beam and leading back down to two EST40 Lewmar manual winches mounted inside of each vertical Arch leg.
With all that in mind let’s go see how Uğur & Nihat, aided by their student intern Omer, made this all come together this past week. I will use the same technique as many seemed to like in covering the build of the Tender; a rapid fire set of photos with just a little bit or text along the way. Here goes………………….
If you would like to review the building of the various components of the Davit Arch system you can look through the past 3 weeks of posts which covered their construction. This week Uğur began by machining the two large cylindrical Hinges; one at the base of each vertical leg of the Arch.
He had welded the two Base Plates out of 20mm/ 3/4” AL plate a few weeks ago so now he was ready to machine the 100mm / 4” OD aluminium cylinders that fit between the two triangular sides on the Base Plates and the two SS Hinge Pins that slide through to create the Hinge. KISS, Keep It Simple & Safe design for the whole hinge with these two SS Hinge Pins that have an end cap bolted on to keep them in place and snug up against the sides of those triangular support arms on the Hinge Plates. While the Hinge Pins were being machined, Uğur and Nihat mounted the AL cylinders into the holes in the 25mm / 1” thick plates at the base of each vertical leg. Some scrap pieces of AL were tacked on to hold the cylinder in perfect alignment and then welded them fully in place with multiple passes on each side. All three parts now complete and ready to be bolted together to form the completed Davit Arch. Aligning the holes in the two doubler plates. And securing them with six 16mm / 5/8” bolts. Torquing down all the bolts, Hinge Base Plates ready to be attached with their SS Hinge Pins. Like this. et Voila! The Davit Arch is upright for the first time and ready to be moved up onto the Aft Deck of Möbius.
But how do we do that when the forklift can’t lift the Arch up high enough??? Simple! Uğur quickly fabricates this Forklift Crane eXtension (patent pending) using some scrap lengths of 8” square steel tubing with a chain hoist and block hung from the top and the base jammed into one of the forks of the forklift.
Oh, and a couple of strong men to help steady the Arch in place. Up Up Up goes the Arch …….. ……… as Uğur inches the forklift into the very tight space between Möbius and Twinity, the big composite catamaran hiding behind the scaffolding and plastic on the Right here. The Forklift was till a wee bit too short for the Aft Hinge Base Plate to clear the deck but some pry bars and muscle helped to raise it the last few inches and the Davit Arch was no up and ready to be positioned precisely on the Aft Deck. The laser level and a long tape measure allowed us to get each Hinged Base Plate in the same position that we had worked out on the 3D model. And each plate was tacked in place so we could do some real world measurement and testing to make sure the somewhat complex geometry all worked out as in the 3D model for getting the Tender to clear the outer edge of the Port/Left Rub Rail and then get it fully on Deck to meet the requirement that no part of the Tender extends out past the vertical line of the outer Rub Rail. A worms eye view from the Swim Platform looking up the Aft Vertical leg of the Davit Arch and a good vantage point to see how the Davit Arch hinges on the Base. Our digital level was a big help in checking the angle of the vertical legs when they are in the fully upright position where the Tender will be Lowered/Raised on the Aft Deck.
We designed this to be just a bit less than vertical so there was always a bit of weight on the rigging when the Tender was hanging from the Davit Arch so the Arch would start to move as you loosened the line on the winch and belayed the line to move the Tender sideways and over the Port side where it can be lowered into the water. Now I needed to see exactly where the Centerline of the keel of the Tender would be when lowered onto the Aft Deck so I scrounged around the yard and found two of these weights. Not sure what they are or used to be but they worked just perfect to be Plumb Bobs that I could string from the top of both ends of the Davit Arch and mark the spot on the deck with my felt pen when the Plumb Bob string was exactly vertical. With the forward and aft Plumb Bob points marked, a laser level and a 6 meter length of aluminium L-Bar provided enabled me to lay out the full centerline on the Aft Deck and then use this as our reference line to measure the position of the Davit Arch and Tender as they moved from fully onboard to fully off the Port side. It took me several hours of laying out all the positions of the Tender and its clearances over the side as well as clearing the Port Vent Box you see off to the Left of the front Hinge Base.
We tried out about three different positions and tacked the bases in each one as you can see evidenced here with some of the previous tacks that were ground off so we could reposition and get that Goldilocks just right spot. You can see some of the different locations and colours I marked out on the deck until I though it was just right. and gave Uğur the go ahead to weld them fully in place. Here is what the Forward Leg of the Davit Arch looks like now fully welded in place. And here is the Aft leg of the Arch now fully welded in place just inside the stairwell down to the Swim Platform. As mentioned up in the beginning, the Tender is lifted Up/Down in the Davit Arch via two of these EST40 Lewmar winches. This is the Aft winch. And this is the Front Winch. These EST40 winches have two speeds and are self tailing which should make lifting the Tender up off its deck chocks and out of the water very easy to do. Once the Tender has been lifted up high enough for its bottom to clear the side deck, moving the Tender sideways onto the Aft Deck is even easier using this much larger and electric EST65 Lewmar winch. You can now visualize how this single line from the winch goes up to the two bridle lines that go over to the front and aft ends of the Davit Arch. And you can now see one of several uses for those two 50mm/ 2” thick aluminium Fairleads extending up out of the Starboard side Rub Rail. Once we have the Tender strapped down into its chocks on the Aft Deck all the weight comes off the Davit Arch and I wanted to make sure that it was well secured when we were on passages. Uğur came up with this simple design of two plates welded to the sides of the roof that sandwich the front vertical leg and …… …. is then captured when the Arch is fully raised and rests against the forward side of the Roof overtop of the Aft Deck Galley. We will make up a pin to slide through the two sandwich plates so that the Arch could not come loose and I may make this with an eccentric cam so I can lock the Arch tube tight against the rubber bumper that will be glued to the Roof edge and make for a nice tight holder that won’t rattle or move. It is difficult to photograph the overall Davit Arch so I climbed up on the racks that separate the far bay in the shipyard to get this photo looking down at the Aft Deck of Möbius and Twinity off to its side.
Hope this helps to also give you a better sense of size and scale to the Aft Deck, Swim Platform, etc..
AFT DECK INSULATION:
In between building the Davit Arch, Nihat got busy putting in the 50mm / 2” thick EPDM foam insulation on the underside of the AL roof that extends out overtop of the two Vent Boxes.
These two Vent Boxes are primarily there to bring fresh air in and stale air out of the Engine Room and Workshop but we put them to double use as our Aft Outdoor Galley by making their tops out of the same Turkish Turquoise marble as in the main Galley and installing a nice SS sink on one side and our electric BBQ Grill on the other. Up to now, the underside of this overhanging roof looked like this and so Nihat got busy filling in all those channels with 50mm thick EPDM foam insulation. Like this. Prior to putting in the EPDM foam, he welded in all the short lengths of aluminium L-bar you see here …. that will be used to attach the White Alucobond ceiling panels which they started cutting out down on the shop floor beneath. This is a view of that ceiling looking up from inside the SuperSalon through the main entrance door. And while he was in an insulation mood, Nihat removed the large AL deck hatch overtop of the Engine Room and glued in all the 50mm thick EPDM onto its underside. As with the rest of the walls and ceiling in the ER, this EPDM will next be surfaced with White Alucobond screwed to those AL L-Bars he has welded into the frame of the Hatch.
Last but not least for this week let’s go check out what’s been happening with the interior of Möbius.
The Captain is VERY happy to see these two SS towel warming racks finally show up at our apartment after months of searching to find them, putting through the order, getting them through Turkish Customs and finally getting them delivered. They are both the same and one goes in our Master Head/Bathroom and one in the Guest Cabin Head. Beautifully made, this is one of the brushed 316 SS valves that connects the towel rack to the SS Hot Water fittings mounted in the walls. Can’t wait to show you what these look like when they’ve been installed so do stay tuned for that in a future episode here. Serkan our Hardware guru, continued with his installation of those lovely SS latches I’ve been extolling ad nauseum the past few months. He is now down to the last of these as he installs the final four on these lower cabinet doors on the Starboard side of the Master Cabin. With so many to install and the need for each latch barrel to be in just the right spot, he has build this little jig to make it easier to drill the pilot hole for each latch. Sinan had previously covered the panels for all the upper cupboard doors and the Bureau of Drawers with their beautiful Green/Blue leather and Serkan now has them all mounted and installed all their SS latches. Looking forward along that same side with the Bed platform on the Bottom Left and the Shower/Bathroom Upper Left, you can see how the Master Cabin is starting to come together. Bathroom door now hung and most of the Bathroom cabinets in place waiting for their Corian countertops and then the iridescent blue glass sink can be installed. Same style glass Blue sink is in place in the Vanity at the very front end of our Master Cabin. The upper part of the door will soon have the same Green/Blue leather panel installed along with the door handle that will look like this. Which is actually the handle installed on the “Swiss” double acting door for the Entrance to the Master Cabin and the tall Wardrobe on the Left. I detest drafts, squeaks and rattles so all the interior doors have these silicone based seals inserted into thin slots cut into the corner of each door jamb. As is so often the case it is the small details like this that make the difference between good and eXceptional and I smile every time I feel the soft squish as I close one of these doors and feel them seal tight as the door latches closed.
In the Absolutely Must Have category as well as the “Don’t ask me how long it took to get these here” category, it put an even bigger smile on our faces when these Crosby anchor shackles finally arrived. Our anchor chain is 13mm / 1/2” but we were able to upsize the critical link between the chain and the anchor to this 16mm / 5/8” shackle. One of the key bits of kit that truly help us Sleep Well At Night or SWAN as we often call it. And THAT my family, friends and followers is a wrap for the week that was September 21 to 26, 2020. Hope you enjoyed this week’s Progress Update and PLEASE let me know your thoughts, concerns and questions in the “Join the Discussion” box below.
Thanks for joining and I hope to see you here again next week.
Another slow week aboard Möbius unfortunately with the combination of lack of staff to another boat ‘Caledonia” that launched on Friday and an unexpected 4 day week due to two workers testing positive to Corona 19. Those two men who had both been working together on Caledonia have been quarantined but and the rest of that team were all tested so we are hoping that we can get back to work tomorrow, Monday here.
However, Uğur and Nihat made great progress on the Tender and I got in some solid days working on Mr. Gee so I’ve got lots to show you and let’s jump right in to this week’s Show & Tell.
Serkan our Hardware specialist, has continued with the installation of all the many latches and gas lifts on the cabinetry doors and drawers in all three cabins. Below is a short little video that will do the best job of showing you how these work.
Now that we get to try these out we really like how our design has all worked out for these Galley Garages. As you can see in the video above, even when you have messy fingers while cooking, a simple flick of your finger allows the door to fully open and move out of the way so you can grab whatever you need inside. These gas filled lift cylinders snap into SS mounting balls which you screw to the inside of the cabinet and the door so while Serkan needed to spend a bit of time figuring out the exact placement of these mounts with the first door, it goes very quickly after that.
I thought the instructions on the plastic bags the cylinders come in would do the best to show you how this works.
The Silver coloured one I’m holding here is a Lift cylinder so it compresses when you close it and is what is used on the Galley Garage doors. The White one on the counter is a “drop” cylinder so it works in the opposite direction to slowly lower our fold down doors where you flip the latch open and then the gas cylinder slowly telescopes out to smoothly lower the door to its fully folded down position rather than free falling open.
Exciting for Christine and I to see that we are now at the stage where our OGM Navigation Lights are getting mounted.
Uğur and I came up with this simple design for the mounting bases that go on each side of the coaming around the SkyBridge for our Red/Green side nav lights. For those not familiar with COLREGS, the standards governing navigation lights for ships of all sizes, this graphic shows the nav light requirements for a power vessel a over 20m/65ft length. For the Port/Starboard Red/Green lights must have a Horizontal View Angle of 112.5 degrees and >70 degrees Vertical so they must be mounted at an angle of 33.75° from the centerline of the vessel. I’ve been using these OGM nav lights for 15 years with great success so sticking with what I know for Möbius. The body is CNC milled out of a solid block of aluminium and then the 2 nautical mile LED sets behind a glass lens and the whole light assembly is “potted” in epoxy so there is nothing to come loose or leak. KISS at its best!
Up on top of the Main Arch we have these 2 OGM lights, a Single White Steaming Light: Visible over a 225 degrees arc forward with the all around 360 degree White Anchor Light mounted above.
Yet to be installed at the end of the Aft Deck is one more OGM that is a Separate White stern light covering 135 degrees Aft. Just up front and off to the Port side of Red/Port light is this GPS head which is dedicated to providing the satellite based GPS data to …………. …………. our em-trak Class A AIS transceiver that is mounted overtop of the Main Helm. We like to have a lot of redundancy for our GPS data so this GPS head is one of five that we have all together onboard Möbius.
Given our speed and size we decided to upgrade the AIS Class B we have had on our previous boats to this Class A unit and the table below explains why.
With Class A we get bumped up to high priority over other boats with Class B, increased power and range broadcasting at 12.5W vs 2W
Dynamic information is transmitted every 2 to 10 seconds while underway and every 3 minutes while at anchor vs every 30-180 seconds on Class B.
Not cheap, but one of our five principles for Möbius is Safety, so when it comes to Safety at Sea we don’t compromise. Courtesy of Digital Yachts site here is a nice graphic (click to enlarge) and overview of AIS (Automatic Identification System).
AIS is the mariner’s most significant development in navigation safety since the introduction of radar. The system was originally developed as a collision avoidance tool to enable commercial vessels to ‘see’ each other more clearly in all conditions and improve the helmsman’s information about his surrounding environment. AIS does this by continuously transmitting a vessels identity, position, speed and course along with other relevant information to all other AIS equipped vessels within range. Combined with a shore station, this system also offers port authorities and maritime safety bodies the ability to manage maritime traffic and reduce the hazards of marine navigation. Due to the great safety benefits offered by AIS, this technology was made compulsory throughout the world in 2002 for all passenger ferries and vessels over 300 gross tonnes.
Nihat is one of our most efficient and hard working members of Team Möbius so while he was waiting for Uğur to lay down more of the finish welds on the Tender, he would move over a few feet to work on cleaning up the welds on the three part Davit Arch.
Here Nihat is working on the long horizontal cross member of the Davit Arch and the thick plate you can see on the far Left in that photo has a matching plate on top of the vertical legs of the Arch. My thinking with this design is that it makes it much easier for us to dismantle the whole Davit and store it on deck when we want to transform Möbius into her “hunkered down” configuration for canals or in hurricane/cyclone conditions when we would also lower the SkyBridge roof.
Prepping for Propulsion:
I was able to spend much of this four day week inside the Engine Room on Möbius getting Mr. Gee ready to have his best buddy our Nogva CPP Servo Gearbox mated to him. This is looking forward at Mr. Gee’s massive 100+Kg flywheel which now has the Nogva aluminium SAE14 frame bolted on.
Each of those rounded “teeth” around the inner circumference will fit precisely with the matching grooves on the hard rubber Flexible Coupling which is bolted to the input shaft of the Nogva Gearbox. Like this. Makes for an eXtremely solid yet eXtremely quiet flexible coupling of the 180 Draft Horsepower coming out of Mr. Gee to the Nogva and on to the CPP propeller. Turning around to get this shot of the SS Prop Shaft protruding out of the AL Prop Log Tube I needed to get the Prop Shaft perfectly centered in the Log Tube so I made up this little jig to do so. Just a short bit of AL tubing machined so it snugly fits into the space between the Prop Shaft and the Log Tube like this. The two halves of the Red Nogva flange you see in these photos will be bolted to the end of the Prop Shaft on the bottom Left here and then this flange must be very precisely aligned with the matching flange on the output of the CPP Gearbox. I’ll show you all that in a week or so.
Mr. Gee Gets Dressed:
Remember that big 24V starter motor you saw being rebuilt and painted the past few weeks? Well here is what it looks like when slid into place on Mr. Gee’s Aft Starboard side. More Gardner ingenuity to make removing the starter so easily, it slides straight aft like an artillery shell into a cannon and you can rotate it to any position and then cinch it up tight with the silver band clamp you see here. I’ve put the terminals on the bottom so the big cables will be well protected by the starter above and have a straight run out below. It also felt great to finally get to fit this Bronze Beauty aka the Engine Oil Cooler, put in place just above the starter and below the Exhaust & Intake manifolds.
Seawater will be pumped into the 90 degree Bronze/Copper pipe at the far end and then out the curved copper pipe in the bottom center here. Up at the Front Stbd/Right side of Mr. Gee is this centrifugal coolant/water pump that is driven by a gear off the timing chain inside the cast AL Crankcase on the Left. The Coolant/water is pumped out through the AL manifold on the Left here and into the two Burgundy Cast Iron Cylinder Blocks. Surrounded my more Beauty, this time in the form of one of our two “tiny” Red 250Amp @24V Electrodyne alternators. Time for me to start fitting these monsters to equally robust mounts I still need to finalise. For this one I’m going to reuse the same method the original Gardner engines did by using strap mounts same as you just saw on the Starter above, to solidly attach the alternator to those three curved you can see are cast into the Crankcase. Then two straps wrap up and around the alternator body and are cinched down with a threaded stud.
As you can see, I also need to finish assembling the big Red Electrodyne Junction Box for all those White wires coming out of the alternator body on the Right. The Junction Box is just sitting loose right now as I measure everything up prior to fitting this in place onto Mr. Gee’s side.
Flip my Tender!
Uğur picked up where we left off last week with some final checks on the critical positioning of the cast aluminium mounting frame which Castoldi supplies with their 244 Direct Drive Jet. That cast AL Mounting Frame is shown in Blue in this render and the Grey plate on the right is a partial view of the 20mm / 3/4” thick AL plate Transom with what I’m calling the “Mickey Mouse cut-out” to create the whole opening in the boat where the Castoldi will bolt to. This is what the whole Castoldi 224DD looks like with the Jet nozzle on the Left and if you look back and forth between this and the render above you will be able to see the mounting holes around the whole jet drive casting and how they will fit into the opening above. Cast aluminum is often a different mixture of the alloys than aluminium plate and can be challenging to weld so we wanted to sure there would be no problems welding this cast AL Frame into the Tender’s Hull plates. Those three cross members spanning the Frame above are temporary so Uğur did a test weld on this one and a small scrap of 6mm AL plate and then we all took turns trying to break the weld with long levers. Didn’t budge or crack so we are good to go. Always a bit of hesitation when it comes to cutting holes in the bottom of our perfectly good boat and especially one THIS BIG! But it was soon done and we’re ready to start installing the Frame.
But first, we decided to flip the hull 180 degrees to make working on the bottom so much easier so strap yourself in and I’ll do another rapid fire set of photos that many of you have said you’ve been enjoying to walk you through the whole flip. Handy having a Forklift is rather handy! One last check fit of the cast Frame into the opening in the Hull.
You can also see the outline of the Mickey Mouse cut out etched ty the waterjet cutter into the Transom. We debated whether to have this Mickey Mouse cut out by the CNC waterjet when all the plates were being cut but we decided it would be better to leave it until now when we could double and triple check its position and get the jet drive in the exact right location.
Aluminium is such a great material to work with and even at 20mm/ 3/4” thick, Uğur was able to make quick work of cutting out the majority with a jig saw while I kept the blade cooled with cutting oil spray. Ta-DA!
I think even Walt would be proud don’t you? Frame tacked in place now ensuring that one of the most critical aspects is that the front edge of the Frame on the far Left here and thus the body of the Castoldi that fits into the Flange, are flush with the bottom plate of the Tender. Seen from above it looks like this. Frame now fully welded into the Hull and Transom. Captain Christine arrives just in time for the start of the Big Flip! Airborne now. 180 degrees, Half way there….. 140 and counting ………. 180! We’re flipped. Nihat wastes no time jumping in with his angle grinder to start cutting the deep V grooves so Uğur can get full penetration with his MIG gun as he follows soon behind with the first full length welds. Like this. MIG welder up and Uğur gets down to business! Time for me to get busy as well as I need to remove a few bits and pieces from the fully assembled Castoldi still sitting inside its factory wooden box.
This is the forward leading edge of the Jet Drive where the water initially enters through the grates underneath the far Left of the cast AL body. I need to remove this electric driven hydraulic pump which powers the Jet’s Steering nozzle and Jet Drive Bucket.
Input Flange where the jack shaft from the 110 HP Yanmar HTE will connect via a flexible coupling and jack shaft. Propulsion direction Forward/Reverse/Sideways is accomplished by moving the big Bucket overtop of the jet’s nozzle which is done by moving the rod in this hydraulic cylinder on the Stbd/Right side. That cylinder above connects to the Bucket like this. I’m very impressed by the design and build of this Castoldi Jet Drive and it only takes me minutes to remove all these parts and have the Jet Drive stripped down and ready to be installed in the hull. A well tuned MIG welder sounds like a very big buzzing honeybee and all the while I’ve been prepping the Castoldi, Uğur has had his MIG gun buzzing merrily away …. as he lays down all those first long lengths of full welds and then goes over them all again with the second final bead. Et Voila!
The bottom of the hull and the Castoldi Frame are all welded in place. We double check that the Frame is still properly aligned and that the heat from all the welding has not warped anything but all is well.
Time to cut out those temporary supports in the Cast AL Frame. And Mickey is now ready to receive his Italian Bride! Who has now also been flipped over 180 and ready to be lifted out of her box and into the Tender. Forklift makes it all very easy and able to lower it slowly in place. And unfortunately I have to leave you and the Castoldi hanging at this point as I was too busy helping Nihat get the Castoldi lowered in place and do all the measuring and checking of the fit to be able to take any more photos. Sorry!!
But I’ll be back to pick up with all this next week so I’ll leave you with this mini cliff hanger for now and hope that you’ll forgive me and join me again next week.
Thanks for joining the adventure and be sure to leave all your questions and comments in the “Join the Discussion” box below.
Similar story this week as the past few; excellent results and exciting progress on Möbius wherever Naval craftsmen have worked, just not as many of them working as are needed to finish and launch Möbius as quickly as possible when they are assigned to work on other projects in the shipyard. But forward progress towards the eventual Launch Date made none the less.
As I gathered all my photos from the past week together there seemed to be a theme of light than shone through many of them in different ways and hence this week’s title. So let me go shine some light on all of these and jump right into this week’s Show & Tell and show you some of those eXcellent results and eXciting progress from this first week of September 2020.
Lots of Light shining through in the interior such as this is one of very many LED light fixtures which are inserted into the removable ceiling panels in all the living spaces. These are made by the big Italian lighting company BCM and we are using their BCM Charlotte 80 LED lights for most living areas.
These are the newest generation LED lights which are significantly more efficient so their wasted heat is very small and the large heat sinks you may be familiar seeing on such LED fixtures are no longer required so these lights are much smaller and cooler, both literally and figuratively.
Typical Italian craftsmanship and quality, they are easily set into the holes cut into the ceiling panels by folding the two spring loaded arms out of the way and then orienting the outer polished SS frame however you wish.
All our lights are LED so our overall energy consumption and heat generation is kept to an absolute minimum and all lights are on dimmer switches so we can easily have the Goldilocks Just Right lighting in every location and situation.
Lights over larger living spaces such as these overtop of the Lounge on the Left and the Dinette on the Right are a Warm White, about 2700 – 3000K.
Whereas task lighting situations such as these in the Galley are a cooler Neutral White of 4000-6000k. We also have some up here in the SuperSalon that can be switched to a coloured Red/Blue light when we are on night passages and want to maintain our night vision. Serkan, our interior hardware installer, continues to make his way throughout the interior installing all the positive locking latches and gas struts the many cabinet drawers and doors. I’ve shown these to you before but I’m still madly in love with what are to me jewellery like SS lifting latches for all our drawers and cabinet doors.
Single finger lift like this to unlatch and then they are spring loaded so they automatically self latch when the Blum soft close feature of each drawer slide gently pulls the drawer closed. Hakan ordered this range of telescoping gas spring struts so we could try them out and chose the ones that were just right for our Garage Doors and fold down cupboard fronts. In the case of these Galley Garage doors, when you lift the latch the gas springs automatically raise the doors to their fully open position and hold them there while you get at whatever you need inside. Whereas for cupboard doors such as these lower two in my Corridor Office where the space behind is too shallow for a pull out drawer, the gas struts gently lower the door down when you unlatch them. In the case of “regular” drawers such as these below Christine’s Office desk, no struts are needed because when you unlatch them the drawers slide out effortlessly on their Blum SS roller bearing drawer slides and then close automatically with the soft close feature when you give the drawer a gentle push to close. The removable Teak floors inside the Heads and Showers have moved on to their next stage of completion with the Black joining compound now all sanded down to a flush surface and are now ready for their fiberglass bottoms to be applied.
Hilmi our one and only “Sparkie” or Electrician continues to make steady progress with all things electrical onboard Möbius which covers a LOT of different aspects from lights you see above to cabling, connections, circuit breakers, switches, controls and other electrical devices ……………
………. such as this UDST 800 Ultrasonic Depth/Temperature/Speed transducer in the Bow. As you may recall seeing last week this transducer is installed inside an otherwise unused integral tank in the hull so that in the unlikely event that we somehow managed to scrape the whole transducer off the maximum amount of water we could take on would be small and self contained within this WT compartment. Hilmi has now installed the N2K cable from the transducer up out of the WT compartment through this cable gland which keeps the tank fully watertight. Up in one of the highest spots on Möbius, Hilmi has all these MC-4 connectors installed in SkyBridge roof for each of the eight 320kW solar panels that form the roof as well as the other six solar panels fore and aft of this. In addition to a fully sealed twist lock connector, we use this model that contains a 15A fuse inside which can be easily replaced with a simple twist. All the wiring in the SkyBridge roof is now installed in these two cable trays that run down each side of the center rectangular AL extrusion that forms the ridge of the roof and then travels down the inside of the Main Arch tubes to make their way down to their connections to the 14 Victron 100/20 SmartSolar MPPT controllers in the Basement. One last bit of electrical detail for those interested are these Swiss made Belimo 24V vent air damper activators. These connect to a set of louvers inside the Vent Box and Open/Close them as required. They are normally closed until they are activated as part of the start up sequence for Mr. Gee, our main engine, and allow fresh air in through the Port side Vent Box and extract it back out through the Starboard side Vent. The dampers are also part of the Automated Fire Extinguishing System which would immediately close off all these vents and shut down Mr. Gee so that the aerosol Fire Extinguishing gas stays trapped inside the Engine Room with no air able to enter or leave and the fire can be quickly extinguished. This heat activated sensor adds an additional level of Safety if the FFE does not work by closing the louvers anytime it senses a temperature higher than 72C/160F. There is also a manual crank that you can use to close/open the louvers at any time in case of an electrical failure.
Fire is probably the scariest thing aboard a boat so we take it VERY seriously and take no shortcuts to ensure that we are alerted as early as possible to any rise in temperature, any smoke or gas or heat and can take action immediately as needed.
AFT SOLAR PANEL BANK:
Light of a different kind or at least purpose was also the focus this week as Uğur and Nihat, along with our student intern “Omer” from Istanbul Tech University, took time away from building the Tender to Möbius to build the racks and mount the three 320kW solar panels that mount on the cantilevered roof above the Aft Deck Galley.
We have 14 solar panels in total which are in Purple in this quick render. 3 on the angled & hinged frame overtop of the Pilot House, 8 which form the roof over the SkyBridge and 3 on the Aft Roof.
Total Solar Wp (peak watts) is about 4.5kWp and each panel is wired to its own Victron 100/20 MPPT controllers in the Basement. As always we did our best to KISS or Keep It Safe & Simple, the design of these racks to mount the three Solar Panels. Four lengths of 30mm / 1” aluminium L-bar with mitred corners. It took Nihat minutes to cut, fit and weld these frames and then he and Omer tested them with the actual solar panels to make sure it all fit just right. With the solar panels removed the three frames were easy to lift up onto the roof where they were tacked together with the center panel offset Aft to match the angled end of the roof and reduce shading from the Main Arch and Paravane A-Frames in front. To make it easy to attach and remove the solar panels, these short lengths of 50mm/2” L-bar were welded to the roof and matched up with same size L-bar brackets around the edges of the Frames which can then be easily through bolted to the brackets on the roof. This enables the solar panels to be through bolted to each Frame and L-bar bracket when they are standing up and their underside is easily accessed. Then the assembled Panel + Frame assembly can be bolted to the roof brackets.
As you saw earlier, the + and – cables hard wired to each Solar Panel have a standard MC-4 twist lock connectors. I had purchased the matching MC-4 connectors wtih built in 15A fuses and the crimping tools for these which Hilmi is using here to make quick work of installing these MC-4 connectors on each cable that will carry the output from each Solar Panel down to the Basement where they connect to their dedicated Victron 100/20 SmartSolar MPPT controllers. Hilmi worked hand in hand with the Framing team to have them mount this cable tray to safely carry the six cables from the Solar Panels over to the cable penetration they welded into the roof. Where the cables are then fed over through the penetration into the interior of the Pilot House where they get routed down into the bank of 14 MPPT controllers in the Basement in an uninterrupted run. All three Solar Panels now bolted securely into their frames, wires routed on their underside and ready to be carefully laid down onto the awaiting brackets on the roof. Like this!
All the other 11 Solar Panels have been fully mounted and connected to their MPPT controllers so these three now complete the Solar Panel installation and all 14 MPPT controllers have their indicator lights blinking away.
Well done Team!
TENDER BUILD CONTINUES
Picking up where we left off last week, Uğur and Nihat make more swift progress on building the Tender to Möbius this week. You seem to be enjoying the rapid fire series of photos as this Tender takes shape so I’ll do the same this week and run through a chronological series of photos so you can watch the Tender come to life.
Here is where the Tender was on Monday morning. Hull plates all tacked in place along with some internal framing and the start of the offset center console. Seats which double as fuel tanks wrap around the Bow on the Right and upper angled section of the Console in the Left foreground. Floor framing and hull plates below. Console on the Right, seat behind and “Engine Room” as Uğur likes to jokingly call it at the aft end. Uğur, checking out the visibility when seated at the Console. He gave it his thumbs up. Raised Bow pulpit shaping up. We wanted to have a wide flat area on the bow to make it easy to board with the bow pressed against a dock of the transom of Möbius.
See the Tender render above to see the whole upper perimeter will have a dense tough foam Fender about 250mm/ 10” wide attached which makes the flat at the Bow even wider and good for being a mini tugboat to push other boats or be the auxiliary power for Möbius in an emergency.
20mm/ 3/4” thick Transom plate tacked in place now.
Note the etched lines with the “Mickey Mouse” ears which will be CNC cut out later. In addition to this cut out in the transom, the cast aluminium frame in Blue here is supplied by Castoldi and will be welded into the bottom of the hull plates to create the opening where the Castoldi 224DD jet drive will slide in and be bolted in place. You can see how the cast AL body of the Castoldi 224DD on the Right will fit into the frame in the bottom of the hull and how the thick vertical plate in the middle will through bolt to the Transom plate. Partially wrapped in bubble wrap from the factory, this is what that cast AL frame looks like.
The three cross bars are temporary braces to keep the frame fully aligned while it is welded into the hull and then these will be cut out and the Castoldi jet drive slid in place and through bolted to this frame. 20mm / .75” thick engine bed plates tacked up. Pulling the two upper hull plates into position to create the Bow. Upper Hull side plates being led Aft and tacked in place. Flat bar tacked below to set the curve of this joint. Scrap bits of AL tacked across the hull plate joint to keep it flush while tacking both in place. Working in Tandem, Nihat presses the two plates into alignment as Uğur moves along with his MIG gun tacking the two plates together. All tacked up and ready to be fully welded once some of the internal frames are set in place. Bow all tacked up. Nihat cleans up the welds before the Bow is welded closed with the top plate. Stepping back to see that the Tender is shaping up nicely. Tack – Tack –Tack.
Bow is ready for welding. Tack – Tack –Tack.
Sides and bulwark tops are all in place. Integral floor framing added in next. Starting to look like a boat! Uğur spends the better part of a whole day laying down the final welds of all those tacked up plates. Like this. And this. Working on his Ninja Warrior Welder look, Uğur cleans up one of the Engine Beds he has welded up and is ready to be welded into the Hull. Like this. Inside of Hull plates finish welded as is the lower strake and the frames for the floors and the sides of the Engine Bay. Floor plates in the Bow seating area lay down quickly along with those leading along the walkway on the Port/Left side of the Tender. Inner side plates now ready to be installed and the Console seat box is tacked up. Captain Christine is called over for a test fit when she is piloting the Tender while seated at the Console. And standing.
The Captain is happy with both so the work can proceed! Console and seat is emerging.
OK, quitting time on Friday so we will pick up from here in next week’s Progress Update.
Hope you enjoyed this rapid fire Tender Build sequence.
STARTING Mr. GEE – TWICE!
No not quite ready for his first real start up, but I did get time this week to finish rebuilding his 24V electric starter motor.
This is a new set of clutch plates which lock the starter gear to the motor shaft as it slides forward to engage with the big ring gear on the flywheel and spin Mr. Gee to start. This is the working end of the starter; the bronze starter gear that engages with the ring gear on the flywheel. A quick visit with the sandblaster and two coats of epoxy primer have the starter ready for its final paint job. In shiny Black. However the start of the starter show IMHO are these bits and bobs which have also been blasted, primed and finish coated with Black epoxy and will soon be assembled into the Hand Cranking starter for Mr. Gee.
Hand Crank lever is in the middle here. This chain drive gear uses the lever at the top to engage with a slotted drive gear on the crankshaft such that when you turn the hand crank handle the crankshaft spins. With the compression release holding all six intake valves open you can get the giant flywheel up to speed, flip the compression release levers off and Womp – WOmp – WOMP, Mr. Gee comes to life! And I can’t wait to show all ye with so little faith, just how this works in the video I will shoot for the first start-up with both the electric and the hand crank start.
So don’t touch that dial! Stay tuned here for the next episode of “As Mr. Gee Turns”
Thanks for joining us and see you again next week.
A full five day work week here for everyone but me it seems as I had mine cut down by almost 2 days while I looked after a hernia that I developed on my Left side last week. Nothing too serious, I had one on my Right side about 25 years ago and apparently my body wanted to keep all my internals symmetrical so time to fix the Left side this week.
WARNING: This week’s intro may be TMI as my children used to often say; “Too Much Information” Dad!, so you are welcome to skip down to the next section below if you prefer.
The medical system here in Turkey is absolutely awemazing, easily amongst the best anywhere in the world and so after a few visits for ultrasound and other testing they did the laparoscopic or “keyhole” type surgery on Monday morning and I was released Tuesday noon and was able to stop in to see how things were going on XPM78-01 Möbius before heading home to rest for the rest of the day.
They ended up needing to put in a 10cm x 25cm (4” x 10”) strip of hernia mesh material which was much larger than they had originally thought because they decided to cover both my Left and Right sides for a more “future proof” reinforcement.
This required three different entry points for the laparoscopes so I ended up with three neat little “bullet wound” looking spots across my lower abdomen which should be fun for future wild tales from Grampa Wayne in the future.
Hence the double meaning of “tender” for this week’s Progress Update as it applies to my condition this week and MUCH more importantly the beginning of the build of the Tender to mv Möbius!
Best of all however is that I’m feeling much less Tender every day and the Tender to Möbius is feeling more and more real by the day.
So let’s jump right into this week’s Show & Tell of the overall progress on XPM78-01 Möbius for this week of August 24 to 29, 2020.
TENDER to “my Möbius” (my = motor yacht)
First for some perspective, here are the basic details for the Tender:
Central steering station with sloped dash area large enough for small navigation equipment, display screen, switches, gauges, etc.
Twin side by side seats at steering station.
Additional seats for minimum of 2 other adults, ideally 4
Built in lockers sufficient in number and size to hold typical items including life vests, fire extinguisher, spare plastic fuel jugs
Diesel fuel tank integral with hull, 80-100 L capacity
Equipped with full cover such that the Tender can be used as the boat’s life raft.
Designed to withstand ocean going conditions with waves up to 4m and wind up to 8 beaufort.
Engine and propeller system will be owner supplied, small likely 3 cylinder diesel with fixed prop.
Tender will have large continuous “bumper” wrapping around both sides and bow sufficiently strong to allow using these Tender to push Möbius and other boats and resist abrasion from rough docks, rocks, etc.
Foam collar will be adhered to a custom built recess in the hull for this foam bumper and have a wide flat section across the Bow for pushing.
Build in support bars on both side of the flat Bow for safety when boarding from the Bow
Swim Step overtop of extruding Jet Drive to fully protect the drive gear when backed into docks, rocks, etc.
Here is what those specs and use case look like when transformed into the final 3D model after many months of working with Yigit and Burak.
We also worked with the engineers at Yamaha and Castoldi who helped get the hull shape, dimensions and weight distribution just right. The Castoldi Jet Drive 224 DD (Direct Drive) ……. …… is coupled to the Yanmar 110HP/81kW
Yanmar 4JH4 HTE diesel engine using a Cardan shaft and a Centaflex flexible coupling.
We think this combination will make for an eXtremely safe, fast, fun and dry ride!
You may recall seeing in last week’s Progress Update that all the CNC cut plate for building the Tender to my Möbius had arrived and first thing Monday morning Uğur started sending me pictures of he and Nihat tearing into that stack of aluminium and starting to assemble all those CNC cut jigsaw puzzle pieces.
Similar to the building of the Möbius herself, this process of assembling precisely cut, numbered and interlocking pieces to build an aluminium hull boat is very similar to assembling a jigsaw puzzle or plastic model airplane kit. As you can see if you look closely (click to enlarge any photo) the CNC cutter is programmed to leave tiny little “bridges” or tabs every so often along the through cuts so that the individual pieces stay part of the whole sheet of aluminium so they can be shipped/trucked very efficiently.
I received a lot of comments from last week’s posting of how much you enjoyed seeing the Davit go together so sequentially so I will do the same below with the Tender by quickly going through photos as the build progresses quickly with a bit of explanatory text along they way. Ready – Set – GO!
Nihat likes to start by wire wheeling all the surfaces to remove the aluminium oxide layer and provide a super clean surface to weld to. Next he uses a cutting disk in an angle grinder to sever all the little tabs and remove each individually numbered piece from the sheet. He sorts all the pieces into stacks of similar pieces such as this pallet with all the Deck/Flooring plates. Thursday morning, Aug 27th, the real fun begins as they start the kit building process by laying the three bottom hull plates on the floor and tacking the vertical frames in place which starts to pull the hull plates into the exactly correct angles. To shape the more complex curved bow, we used an Origami boat building technique which our Rhino 3D modeling software makes very easy. This process begins by creating a 3D model in Rhino (thanks Yigit and Burak!), and you refine the shape of the model using hydrodynamic testing to come up with the Goldilocks or Just Right shapes and angles for the use case the hull will operate within. Then Rhino3D has a “Flatten” function that creates the paths for curved CNC cuts.
In this photo you can see the first Starboard/Right side hull plate laying flat awaiting the Port/Left plate to join the party. Captain Christine joins Omer & Uğur to get a sense of the shape and scale of our new Tender. Aluminium bars are tacked in place to provide temporary attachment points for the chain tackle to pull the curved cuts into contact with each other. This proceeds in stages, welding the plates where they touch as you work your way forward. Uğur ‘s keen eye is constantly checking as he pulls the two halves together to ensure that everything stays perfectly aligned as he welds the seam to join the two plates into the finished bow.
To assist with keeping all these compound curves all aligned with each other they have also now tacked the two strake plates to the top outer edges of each hull plate. This strake helps the water flow both lengthwise and sideways to deflect the bow wave off to the side rather than up the hull and onto those of us aboard. Similar process is used to now add the next row of hull side plates and pull them into alignment with the lower plates and strakes and tack them in place as the build continues. View from the top makes it easy to see how this all comes together. With the Bow end tacked in place Nihat and Uğur clamp the rest of these side hull plates into position and ………… ………………… tack them along the whole length of the hull like this. Looking at the stern from about the waterline level you can see the profile shape of the hull which is what a jet drive boat wants. Also makes for eXtremely small Draft so we can travel through very shallow waters with no damage to the coral and nature below or to the hull. Integral fuel tank has three sections, one on each side which flow into the deeper compartment on center in front. The very front bow compartment will be for storage of things like anchor & chain. Nihat starts adding in the frames inside each tank and tacking those in place. First frame of the center console being fitted. This will have monitors on the upper sloped surface with controls and steering wheel below and double seat aft. There will also be an acrylic windshield extending above the top of the AL console for added wind and water protection for the pilot. Port side console frame helps to fill in the overall shape and size of the console which is asymmetrically positioned to extend all the way over to the Starboard/Right side hull at the bottom of this photo and leave a walkway on the opposite Port/left side. Uğur and Nihat are a great team so the Tender progresses quickly as Nihat tacks the pieces in place and Uğur follows behind doing all the finish welding. Still lots of jigsaw puzzle pieces to be added!
Omur our student intern from Istanbul Technical Institute helps out by holding this upper coaming plate vertical for Nihat to smooth the curved edges from where they were attached to the CNC cut plat originally. Console all tacked up as is the framing for the Floor/Deck plates fore and aft of the console and under the seat base. Just for a test fit right now this inner side plate will wait for the internal welding to be completed before being slid into place and welded to the hull. Burak kindly plotted some larger scale 2D drawings and shots of the model which Uğur has mounted on this board beside the Tender with Möbius looing on from behind. 25mm / 1” thick AL Engine Bed plates being test fit on either side of the “Engine Room” area aft. Up near the Bow, Nihat has the one piece top deck plate ready for Uğur to weld in place. As with the main hull of Möbius slot welding is used to weld AL plate to the frames that are inaccessible underneath. As we have been doing most weeks, we are working on Saturdays to try to make more progress so this is where the Tender build was at when we finished the day yesterday. Did I mention that day time temps are running 34-38C / 93-100F? Add all the heat from the MIG welder and you have three VERY wet Tender Builders! Uğur takes a well deserved pause to survey the days work and let the air blow over him from one of two big squirrel cage fans we have setup to blow air across the Tender.
I hope you enjoyed this whirlwind tour of the past three days and this photo is how the Tender build looks at quitting time yesterday. Tune in again next week and I’ll walk you through the rest of the build of the Tender to my Möbius.
DAVIT ARCH BUILD:
Lest you think that the Tender was all that Nihat and Uğur worked on this past week, they also finished building the hinged Davit Arch that we will use to move the Tender On/Off Möbius’ Aft Deck.
This is the first test fitting of the three individual segments that make up the Davit Arch. Two vertical legs on each side which are bolted to the horizontal cross beam above. One of the vertical legs on the Upper Left here and the upside down cross beam on the Right. For added strength these additional 25mm/1” plates will span the connection between the horizontal beam and the short angled pipes that connect this to the vertical Arch legs. Uğur quickly has them fully welded with multiple passes of his MIG gun.
The plate spanning the two braces will also provide two addition attachment points for the 6:1 blocks and Dyneema the Tender will be suspended from. Now time to build the two Hinged Base assemblies where the bottom legs of the Davit Arch connect to the Aft Deck. Two of these 25mm/1” thick base plates will attach to the Aft Deck and support the large Hinges. These two triangular vertical plated form the outer sides of the hinge with the 50mm/2” SS hinge pin fastened in between. Due to the camber of the Aft Deck and the different offset from the boat’s centerline, the two hinges are at different heights above the deck. These two very thick tubes are the third part of hinge and will be machined to slide between the two vertical triangular pieces above. These tubes will be inserted into these large holes in the bottom of each Arch leg where they will captured between the two plates on the Base and rotate on the SS hinge pins that slide through all three parts of the hinge.
Stay tuned for mounting this to the Aft Deck and testing it out in the next week or two.
Mr. Gee Gets All Glossy
With my shortened week I didn’t get as much time to work on Mr. Gee but I was able to do some more painting and clear coating on Saturday including a good clear polyurethane coating of this aluminium beauty. This is the rarely seen back side of the massive fuel inject pumps and governor assembly that bolts to the Port/Left side of Mr. Gee. Sorry for the poor lighting but this is the side you see and where all the action happens with the fuel injection system. The six vertical levers for example are what you pull to prime each cylinder and the high pressure injection pumps are located right behind them.
Burgundy part in the foreground is bolted to the flange above it and pumps engine oil through that massive solid Bronze oil cooler/heat exchanger on the other side of Mr. Gee that you’ve seen me rebuilding in previous postings.
These instructions are cast into the large aluminium Header Tank at the front of Mr. Gee which is like the plastic bottle on your car’s engine where you check and add anti-freeze/water.
I’ve painted these with matching Burgundy and next week I will polish off the tops of the letters to make them a bit easier to read and add a bit more class to Mr. Gee. Same thing will happen to the instructions cast into this timing chain adjuster lever.
And these cover plates which bolt to the sides of the cylinder heads.
Mr. Gee’s Best Buddy; Nogva CPP
You might think that Captain Christine is “just” the Captain, she was also called up for our all hands on deck work schedule and spent two very hot days cleaning, sanding and masking the Nogva CPP Servo Gearbox that will soon be bolted to the back of Mr. Gee.
Mr. CPP may be small but he is mighty and provides the 2.95:1 gear reduction to Mr. Gee’s already slow spinning crankshaft.
With a CPP, Controllable Pitch Propeller, we don’t have a transmission per se as we go from forward to reverse by simply changing the pitch angle of the four prop blades.
It is called a Servo because it also houses the hydraulic controls that move the Pitch adjusting rod that runs down the center of the prop shaft where it connects to each prop bladed inside the hub of the prop and rotates the four prop blades in unison to whatever angle of pitch we want. A VERY cool bit of kit BUT we can’t have his Nogva Red clashing with Mr. Gee’s Gardner Burgundy now can we?? So a new paint job was required and hence the big cleanup and sanding this week. Uğur kindly helped move the Nogva to the far corner of the shipyard near where they are building the Tender so I could paint it there with the big shop doors open. Nogva smartly provided a purpose built lifting eye that is centered on the weight of the CPP so we used that to suspend it from the forklift which made it real easy to paint with no supports in the way. Christine had done a great job of cleaning and sanding as well as masking off all the rubber hoses, pressure and oil level gauges and al the instruction and labeling plates riveted to the case which made my job of painting him very quick and easy.
At least until THIS creepy single hander guy showed up!
Between us though, we soon had Mr. CPP ** resplendent in his matching Gardner Burgundy coat and ready to be lifted aboard Möbius and bolted up to the anxiously awaiting Mr. Gee next week.
** If anyone has a better suggestion for a name for Mr. Gee’s best buddy and our CPP, please add it below in a comment.
FRIDGE & FREEZER INSTALLATION
If you were with us last week you saw the initial fitting of the two 130L Door style Fridges in their Ro$ewood cabinets on the Left and the two 70L Drawer freezers on the Right. Monday morning the refrigeration team returned to charge all the compressors with their respective refrigerant; Freezers with R290 and the two Fridges with R134A. The reason for the different gasses is that the Drawer Freezers are a brand new model from Vitrifrigo and they have changed to using R290 which is a friendlier and more efficient refrigerant than the much older R134A standard in most compressors. However it is not possible to mix the two or simply change refrigerant so we have to stay with using two different refrigerants. Not that big a deal just means I need to carry a supply of each onboard to use with my vacuum pump whenever a need to fix and recharge the compressors might happen in the future. Down in the Basement, directly below the Fridge/Freezer cabinets the four 24V Danfoss/Secop compressors are now fully mounted and recharged. We ran them for a day and pulled them down to their lowest temperature settings and they all passed with flying colours. Christine and I can hardly wait to be filling these with provisions when we get ready for our Maiden passage.
SPARKS CONTINUE to FLY ABOARD Möbius
Hilmi our head “Sparkie” aka Electrician was about the only one left of Team Möbius to be working onboard this week but he was his usual busy self and persevered by powering through his still quite lengthy list of electrical jobs needing to be done before we can launch.
Interior Lighting is one of those lists and that is nearing completion as evidenced by all this bright “stars” above the SuperSalon. Each one is a fully dimmable LED so in addition to having eXtremely low amp draw they also allow us to fully control the amount of light in each space. Each LED looks the same on the outside for esthetics but they are all different on the inside for their different purposes. Some such as these task lights in the Galley are bright White and higher Lumens so the Chef always has just the right lighting when working in the Galley. Other locations of warmer light and lower Lumens to best suit the activities there. More exciting lighting up in the SkyBridge this week as Hilmi mounted and wired the LED light bars on the “ceiling” up there. Christine and I are still debating how best to finish off these surfaces of the undersides of the eight solar panels that form the roof/ceiling of the SkyBridge.
Our top priority is to keep a good cool air flow over the undersides of all the solar panels to remove the heat they generate as as heat reduces the efficiency and output of a solar panel to an eXtreme degree. However we also want this ceiling area to be attractive and in keeping with the style and esthetics of the rest of Möbius so we are pondering different ways to do this. For now however and to keep things moving forward as fast as possible we will leave this ceiling as is and go with the “industrial’ and fully functional look that is very much in keeping with the exterior of Möbius. Hilmi has installed these 50mm/2” wire trays down both sides of the center “ridge” extrusion and is also using these to hold the MC4 solar connectors. We took the KISS Keep It Safe & Simple and I believe more efficient approach to fusing each solar panel by using these MC4 solar twist lock connectors which also have 15A fuses inside them. No extra wiring, no fuse box, easy to access, what’s not to like? Speaking of Industrial and Fully Functional, Hilmi finished off the installation of these goodies on the inside frame of the big AL hatch into the Forepeak.
The box on the far Left has the plug in for the hand held remote control for the Maxwell Windlass which is hiding under the cardboard box on the Left and this handheld remote will normally be in the holder on the Right.
The large Blue receptacle is where the Forward Shore Power Cord plugs in and the box on the far Right has the requisite RCCB or Residual Current Circuit Breaker. The traditional marine “Twist & Lock” shore power plugs like this one used in North America are an abysmal design IMHO. Quite frankly they “spark” great fear in me given how poor their electrical connections between the plug blades and the socket receptacles are. Poor connections create resistance which creates heat and leads to these plugs literally burning out on almost every boat I know. I strongly suspect these Twist & Lock shore power plugs cause more boat fires than we will ever know. In any case they are forbidden on our boat and we instead use these CEE style plugs which have three round solid brass rods. For marinas which only have the Twist Lock style we carry adapters like these to adapt our CEE Blue plugs to the Twist Lock style AND these say ON THE DOCK and not on our boat! Our 220V @ 32A Shore Power cords plug into the boat at either this plug in inside the Forepeak ………….. …….. Or this one in the Aft end of the Workshop by the WT door from the Swim Platform.
These RCCP Residual Current Circuit Breakers or ELCI Equipment Leakage Circuit Interrupter are now required on all CE/ABYC compliant boats. These are very important safety devices which provide whole boat protection similar to what the GFCI circuit breakers you have, or should have, on the 120/220V plugs in bathrooms and kitchens. We are using Schneider for all our AC electrical equipment and this is the RCCB we are using which must be located immediately after the Shore Power entry into the boat, hence one in the Forepeak and one in the Workshop. One last round of exciting work from our Sparkie Hilmi is the installation of the ultrasonic Depth/Speed/Temp “triducer”. This is our last, I hope, open hole (purposeful) on Möbius so we are now fully water tight. Yeah!!! The Airmar UDST 800 is a relatively new technology for measuring Depth, speed through the water and sea temperature.
See video at the link above for a quick easy demo. The eXtremely welcome innovation is that the speed sensor has no moving parts such as the paddlewheels we’ve had to use on all previous boats which last for just hours sometimes before they foul with marine growth and stop working.
By using an Ultrasonic sensor the UDST 800 has just a smooth glass surface in the water which will rarely foul and is easily cleaned ever few months with a quick wipe. I chose the location for this forward depth transducer, we have a much more powerful and bottom discriminating sensor Aft, so that it would be inside this otherwise unused integral tank. If you peer down into the open access hatch (click to enlarge) you an see the AL pipe welded into the bottom hull plated and now the Black plastic outer housing is in place where the UDST 800 will be inserted from up here inside the Forepeak.
Why here? Well, if we should ever have a serious grounding of the bow or a collision that managed to clean off the flush transducer, however unlikely, it means that the most water we can take on is what would fill this relatively small WT compartment. Close up of the plastic housing with its very clever self closing flapper valve which allows you to pull the transducer up and out while still in the water and it will close off the gusher of water wanting to pour in while you push the blanking plug in place while you clean or maintain the UDST 800 at your leisure inside the Forepeak.
We were very disappointed and saddened to find out while I was in the hospital that Omur, who has been our Lead Cabinetmaker for the entire interior build on Möbius the past two years, is no longer working at Naval. However his craftsmanship lives on and before he left he was able to finish off the matching Rosewood drawer and door fronts in the Galley such as this bank of drawers on the peninsula by the Entryway door. Even surrounded by all the protective covering you can get a sense of the quality of Ömür’s work and how he prided himself in always being able to find the Goldilocks Just Right combination of matching grain patterns. I have learned in my short life so far that it is the little things in life that often make the big differences and these beautiful solid SS latches is one of my favorite examples onboard Möbius. Richard, one of our faithful followers, was instrumental in helping me track down the producer of these lovely latches that I had seen several years previous but could not find again.
Trying out a test mount in a scrap of plywood, you can see the nice big solid SS latch hook on the inside. On the upper inside framing around each drawer the matching SS latch plate could not be simpler or easier to install like this. Here is how they look when mounted in our drawers.
To operate you just hook your finger under the lower edge, Gently lift up against the built in spring pressure to release the latch and the drawer slides out effortlessly on the SS ball bearing Blum drawer slides hidden away below the drawer bottom. When you have gotten what you needed out of the drawer a gentle push slides the drawer back into its closed position with the automatic soft close feature of these Blum drawer slides and the drawer is again solidly latched in place. No forgetting to lock them before you head out to sea or some passing boat’s bow wave sets you rockin’ and the drawers all slide out.
More features we can’t wait to start living with aboard the Good Ship Möbius. And with that, I shall bid you adieu for this week and go rest my still somewhat tender little body for the rest of this Sunday evening. I go back to the hospital tomorrow morning for a checkup and to remove the bandages and then I should be all good to go and be fully recharged and ready for the final push to finish Möbius and get her launched ASAP.
Thanks for coming along for the ride this week and hope to see you here again next. As always PLEASE put in your comments, questions and suggestions in the “Join the Discussion” box below and add any feedback that will help me improve these weekly Progress Updates and make them more valuable and fun for you to receive.