Team Möbius might not be back to work yet but two of our sub contractors were and Wow! did they and we ever make some great progress and hit some very eXciting new milestones. As per the title both of these sub contractors were in the glass business, one with “real” glass and the other with the acrylic based often colloquially referred to as plexiglass. For simplicity and clarity, I will use glass and plexi in this article.
By whatever name you prefer, we were definately up to our ass (ets) in glass this week. We have glass for all the 360 degrees of windows surrounding the SuperSalon or Pilothouse, glass in all the 10 deck hatches, another 360 degrees of tinted glass around the bottom panels of the SkyBridge coaming, glass for the Guest Shower door, glass tiles in the Master Head/Bathroom, plexi for the 360 degrees of windows around the entire SkyBridge, and then of course the “pièce de résistance en verre” the etched glass corner walls for the Master Shower.
As you are about to see then, it is really not just typical eXaggeration from your author to say that I was up to my assets in glass this week! And before I torture you any further with this play on words, let’s just jump right into this week’s Show & Tell so you can see for yourself.
Pilothouse/SuperSalon Window Glass
There were a bunch more milestones this week but the biggest one for Christine and I was to see this truck load of glass from Hakan Glass here in Antalya, arrive with all the glass that will close in the whole Pilothouse.*
* This area of our boat and all the XPMs can be called either Pilothouse, Wheelhouse or our moniker of “SuperSalon” but for clarity I’ll stick with just PH for the rest of this article OK?
BTW, many of you might be surprised to know that Turkey is one of the world’s largest glass manufacturers! With thanks to Baris at Naval Yachts for providing me this information, you can check out the factory where our glass was made HERE. This will give you a bit more information on “Paşabahçe” which is the biggest glass factory in the republic of Turkey’s and responsible for making glass one of Turkey’s top industries economically. For those interested in more about the long history of glass manufacturing in Turkey be sure to check out THIS site that does a great job of walking you quickly through the history from when Atatürk started all this in 1934.
The reason this is such a big milestone for us is that once all the window glass is installed around the 360 degrees of the PH along with these square glass pieces which will be adhered to each of the ten Deck Hatches, Möbius is WATERTIGHT!
As you may recall seeing in previous months, all the Watertight doors are in and so once the PH and Deck Hatch glass is all in, we are fully weather and water tight! In addition to the glass windows for the PH and the Deck Hatches, the truck also had the slender glass panels that wrap around the bottom edge of the SkyBridge coaming. First challenge though was to get each of these eXtremely heavy pieces of glass off the truck ……………… ……. up the stairs leading up to the Swim Platform ………..
……. then up the winding stairs onto the Aft Deck ………….. …… and then onto the wood pallet on the Aft Deck …….. …….. where they will be stored before being moved into their respective aluminium window frames.
Whew! This shot showing the edges of two of the PH glass windows on the Left and 7 of the Deck Hatch glass panels will help you see why these glass panels are so heavy. The PH glass windows are made from triple laminations of 8mm / 5/16” thick glass and the Deck Hatch glass is made from double laminations of 8mm glass. With three 8mm glass laminations plus two layers of laminating adhesive which are each about 1mm thick, each of the PH glass windows ends up about 26mm or just over 1” thick. These are but a few of the glass windows required:
20 pieces for the PH windows
12 pieces for the SkyBridge “eyebrow”
10 pieces for the Deck Hatches
Each one of these PH glass windows have been custom cut to match the exact sizes of plywood templates the Hakan Glass team had made a few weeks ago so each one is a bit different but on average each window weighed about 22kg / 48 lbs and so this all started with a LOT of heavy lifting! For adhesive, after consulting with the application experts at Hakan Glass and at Sikaflex, we chose Sikaflex 296 along with ….. ……. with SP-206GP primer.
This is the best combination for structural adhesion between glass and aluminium and is often what you see used on commercial buildings whose exterior surfaces are clad with glass. The process begins with the application of the Sikaflex SP-206GB primer that goes on both the aluminium surfaces that the glass will be bonded to ………. ……….. and the inner perimeter of the glass that will be adhered to the aluminium. Once the primer is cured, each window can be carefully carried from the Aft Deck to its respective window bay. Then a thick bead of Sikaflex 296 is laid down around the outer perimeter of the aluminium window frame. Having the right tools for the job always helps and this Milwaukee cordless caulking gun sure beats all the years I’ve had to hand pump window caulking.
The triple aluminium suction cup is one of many we used to lift the window glass into place and push/pull into the right position. Previously that day I had gone around and pulled the leather window mullion covers away from their frames where we have used the new plastic style of “velcro” to hold them in place and I had run a wide strip of Blue painters tape along the Rosewood edges in case any of the Sikaflex oozed its way there. Next PH window glass ready to be lifted into place … ….. and pressed firmly into place. The Sikaflex 296 both bonds the aluminium and the glass to each other as well as filling in the gap between the aluminium faces of the window frames which can have a bit of waviness to them, and the perfectly flat glass surfaces. Typically the thickness of the Sikaflex ends up being about 5mm / 0.2”. small wooden spacers are used to keep the glass edges an equal distance away from the AL frames. Some scrap pieces of Teak (who knew there was such a thing??) were pressed into service to act as spring loaded pressure clamps …. …….. to keep these negatively raked front windows tight up against the frames overnight while the Sikaflex cured. Similar process on the other end where there are three panes of glass along the Aft end of the Galley. It is pretty much a “rinse and repeat” process from there to put all 20 glass windows into place. Pardon the mess but this will help show you how it all looks from inside. This is the Aft Starboard/Right corner of the SuperSalon where the Galley is. This is looking forward from the Galley towards the Bow. If you look closely you might be able to see that these five front windows are all completely clear glass where the rest of the side and rear windows have a slight Gray tint to them as they have a UV blocking film on the inside surface of one of the laminations. With no glass in the Left window and one of the tinted ones on the Right you can see the amount of tint the side and rear windows have.
Tinting is one of those things you want to get to that Goldilocks just right point but it is difficult to judge or calculate other than by experience in situ. So we will live with the glass like this for the first year or so and then decide if we want to add a film to the inside surfaces for more privacy blocking or heat blocking as some of the newer window films that are now available are truly amazing.
This is how the outside is shaping up when viewed from down on the shop floor.
Also a preview of what I’ll show you next which is the glass “eyebrow” around the bottom edges of the SkyBridge coaming up above.
Clint Eastwood’s Squint
This early rendering will help show you how the exterior will look when all glassed in and you can see the thin band of tinted glass that runs around the edge of the coaming (walls) of the upper SkyBridge. Several years ago now when we were working with our awemazing NA and designer Dennis Harjamaa at Artnautica Yacht Design in Auckland NZ, he jokingly remarked that the combination of shapes …… ……. of the narrowing vertical height of the PH glass as it makes the transition forward/aft along with the thin upper height of the tinted SkyBridge glass, reminded him of that squint that Clint Eastwood made famous in his early western movies. We all got a good laugh out of we have kept referring to the Clint Eastwood Squint ever since. Clint is always a good guy to have on YOUR side so we figure this helps add to our “Don’t mess with me!” look. Here you can see the framing that wraps around the SkyBridge. The narrow bottom frames are about to be filled with tinted glass and next week the upper frames will be filled with plexi. Same process as with the PH glass; apply the Sikaflex Primer to the outer perimeter of the AL frames and the glass …….. ……. run a generous bead of 296 around the AL frames …….. ….. and press the glass into place.
Rinse and Repeat. Aft Stbd/Right corner all done. Front 3 panels in place too. Here is how it looks so far when viewed from the inside.
And here is what it looked like by end of the day on Friday.
Last two PH windows still to go in next week.
Deck Hatch Glass
We have a total of ten hatches spread out on the decks of Möbius and they all have double laminated glass lids on them.
You may recall seeing these Deck Hatches which I designed back at the beginning of the build and then Team Möbius built them in house. They have been sitting and waiting for their glass tops so it was eXtremely exciting for me to see this last part of the puzzle fit into place.
Each hatch will have one of these double laminated glass panels bonded to them. Two 6mm glass laminations with about 1mm of adhesive and the thickness of the black film inside creates eXtremely strong glass lids that are about 14mm thick. The hinged aluminium hatch lids are made from 10mm / the 3/8” thick AL plate and so each of the glass hatch lids have black film sandwiched between the two laminations that matches up with the shape of the AL lids where they will be bonded to the glass. First Deck Hatch to get its lid was this one on the Port/Left side of the Aft Deck.
We carry quite a few of these suction cup tools with us as they come on handy for SO many different jobs. We use them to give us a handle on the bottom of the hull when we are cleaning it every few months Hookah “Snuba” setup and we also use them to remove and replace the FastMount panels on the interior of the boat. This hatch is directly overtop of my workbench in the Workshop down below and I can already feel those breezes wafting down on me and the sunlight pouring in as I work down there. The Hakan boys prepping the AL hatch lid in front of the Port/Left Vent Box which is #4 in the hatch layout diagram up above. You can see the shape of the AL lids with their cross bar that matches up with the black film you see on the hatch glass. Same process repeated as with the PH glass; first apply the Sikaflex primer to both the AL bonding surfaces ……. and the glass surfaces. Butter the AL with a generous bead of 296 and press the glass into place. Sikaflex 296 takes several hours to cure so you have lots of time to nudge the glass into the Goldilocks position so that the gap is perfectly even around all four sides of the hatch opening. Both of the smaller 400mm / 16” hatches in front of the two Vent Boxes on the Aft Deck are all done. These two Vent Boxes also create our Outside Galley. Seen from the Stbd/Right side of the Aft Deck to see those same two hatches as well as the larger 700mm / 28” square hatch underneath the spiral staircase leading up to the SkyBridge. These are numbers 4, 5 and 6 in the hatch layout diagram above. Popping up into the SkyBridge to check out Hatch #7 on the “day bed” up there beside the SkyBridge Helm Station.
Our Llebroc Helm Chair is what is underneath all that plastic wrapping in case you are wondering.
This hatch will be eXtremely helpful and open most of the time as it allows us to easily talk with each other when one is in this Upper Helm and the other is down below in the Galley or SuperSalon. Also makes it easy to pass up a coffee or meal from the Galley below. Here are a few shots of how these hatches look from the inside. This one is about centered in the Guest Cabin which will most often be configured as Christine’s Office. This smaller one is directly above Christine’s Office desk so she too will have plenty of fresh air when this hatch is open and lots of natural sunlight all the time. Lots of fresh air and light pouring into the Guest Shower as well. Back up on the Aft Deck, I wanted to double check the glass clearances so I brought up one sheet of TreadMaster that we will soon be applying to all the deck surfaces. The Treadmaster will be about 5mm thick once glued down with West Systems epoxy adhesive so I designed the hatch geometry such that the top surface of the glass sits about 2mm above the AL Deck surfaces. This way the glass surfaces will be just slightly lower than the top surface of the Treadmaster and be very foot friendly.
For those wondering, we will be putting multiple strips of non skid tape across each Glass Hatch so they are very safe to walk on.
GUEST SHOWER GLASS
Based on your comments, many of you will think that I have saved the best for last as all the glass for our Guest and Master Heads/Bathrooms and Showers also arrived this week! Different company that specializes in shower glass and they arrived on Thursday as well to do the installation. This is the simplest part, the clear glass door into the Guest Shower. This door has a full height anodized AL hinge that bolts directly to the Rosewood door jamb. Then a matching AL channel on the opposite side …. …… with the magnetic silicone seal, handle and latch.
Works great in the “dry run” and we will test it out with a real shower after we launch.
MASTER SHOWER GLASS:
Moving up to the Master Cabin Head/Shower/Bathroom, they installed this clear glass separator between the Shower on the Left and Bathroom counter and cabinets on the right. As you can see we designed this partition to stop short of the ceiling so that all the fresh air pouring in through that big 700mm square hatch up above can flow into both the Shower and the Head/Bathroom. And as if we didn’t have enough going on aboard Möbius Thursday and Friday, the tile man showed up to install the glass tile accent on the side wall of the Head! Christine had picked these glass tiles out months ago and they have been patiently waiting to come out of their box and be where they belong.
Wasn’t a big job so he was literally done in less than 2 hours and we think this little detail adds just the right amount of colour and texture to this otherwise all white room.
But of course what really stole the show this week is this “pièce de résistance en verre” , the two etched glass corner walls for the Master Shower. The more narrow 700mm wide wall panel goes athwartships and then the wider 1200mm panel goes in lengthwise to create this gorgeous etched class corner. Very simple mounting of the glass into rabbets in the Rosewood panels surrounding each glass plate which are then filled with clear silicone to hold them in place.
Blue Painters tape and some wood shims at the bottom were all that are neccessary to get them all lined up and ready for the silicone adhesive/sealant.
BTW, ALL of the credit for this work of art goes to our dearest friend Sherry Cooper in Vancouver BC. If you have not already seen THIS blog post from two weeks ago where I covered her work in more details, please do go check that out.
If you don’t have time for that and want to find out more about Sherry you can check out her other works HERE and HERE as well as her Instagram page HERE. Below is a quick synopsis of what I wrote.
Christine and I worked with Sherry to describe as best we could what we wanted to achiever with these etched patterns which was things such as a marine/nautical theme, a taste of First Nation people’s art from the British Columbia area we know and love and to have all this captured in a somewhat abstract and ethereal way.
This is what Sherry came up with and we think the nailed it! A perfect example of our favorite Goldilocks; just right, just for us type of result.
Stepping back a bit to try to show how the whole thing will look when done. Even with all the plastic protective coating and painters tape this work of art and engineering shines through with almost blinding beauty.
Difficult to capture the inside of this small space but this will hopefully give you a rough idea of what the finished shower will look like and just how magical it will be taking a shower in here every morning!
I got more work done on the cogged belt drive system that is going onto Mr. Gee to drive one of our two Electrodyne “Big Red” 250Amp @ 28V alternators and the Jabsco sea water pump but it is already very late Sunday night here so I will cover all that for you next week.
But WAIT! There’s more!!
Speaking of “assets”, the winter rains are about to arrive here in Antalya, as early as tonight according to Christine’s weather apps so we took advantage of today being a truly sunny Sunday, to go for a nice long bike ride along the eXtremely well done bike paths along the 20+ kilometers of the crescent shaped beachfront that Antalya stretches along. Like most places in the world right now we are under stronger restrictions but we are allowed out in the mornings so we took advantage of that for this bike ride and stopped for a lovely little picnic lunch on this stone beach section for an hour or so before heading home to write up this blog. The Med here is still plenty warm enough for swimming and it was almost too hot in the sun here just before noon. All of this adding to the hundreds of other things that both Christine and I have to be SO thankful for as we wish all our American friends and family the very best for their Thanksgiving weekend.
Thank you all SO much for taking time to join me here again this week AND for adding your comments and questions in the “Join the Discussion” box below!
Hopefully Team Möbius is back next week and we will have much more progress to show you.
Merhaba as we say here in Turkey, to all our faithful blog readers. Just for a change of pace, this is Christine here and I wanted to let you know that we have heard all your many requests asking for a video tour showing the current stage of construction of our new boat and home Möbius. So it is with great pleasure that we are finally able to honour your requests.
It had been a year since the last full video tour, and lots has changed for sure. Wayne just loves to talk and write – at great length – about his beloved Möbius, so one day he just took the camera and spent the next several hours walking through the boat and talking about it. That was a few weeks ago now on July 15, 2020
Wayne is far too busy working on Möbius right now to do the editing, so I took it upon myself to learn a new program (DaVinci Resolve, for those who are interested) and start my new career as the Möbius World video editor. I apologize for taking so long to get this done, but it had been a long time since I had done much video editing and the program is complex.
Also, there was A LOT of footage to take on for my first project; thanks Wayne! So I decided to divide it in half and create a two part series for you, Part I of the Exterior of Möbius and Part II of the Interior, both of which you will find below.
First, a few notes about what I’ve done to these videos so you know how best to navigate your way through these quite long videos to get at just what you want.
For those who want to skip through and just look at the portions of the video that interest you, I’ve divided the video into chapters which you can access two ways.
When viewing these videos on YouTube if you look in the text area below the video window, you will find a list of the Chapters in this video. Click on any of the topics in that list to jump directly to that Chapter in the video.
When watching the video if you hover your cursor over the bottom of the video window the timeline will appear at the bottom of each video and you will see some dashes or marks along that timeline bar where each Chapter starts/ends. If you hover your cursor over any bar a pop up text will tell you the name of that Chapter and if you click it will jump directly to that point in the video.
Here is are the lists of the Chapters in each video to give you an idea of what you will find when you watch the videos by clicking on the two video windows below.
For those who might not have seen or remember the line from the movie “E.T. the Extra-Terrestrial”, this week’s title is in reference to the tag line in that film where the homesick little Extra-Terrestrial kept asking “E.T. Go Home?”. Unlike Spielberg my little friend Mr. Gee is definately not imaginary but he has been asking me the same question for a very long time now; “Mr. Gee Go Home?”. So it was a very special day on Monday this week when I got to grant Mr. Gee his wish and move him into his new home inside XPM78-01 Möbius.
While we remain very understaffed with many members of Team Möbius still working on other boats, those working on Möbius this week made great progress and we saw more exciting milestones this past week here at Naval Yachts so I’ve got lots for this Show & Tell.
Oh! And be sure to pay close attention as you go through this week’s Update as Captain Christine has more than one eXtra special surprise gifts for all of you.
So as our 4 year old granddaughter Blair likes to say “Let’s DO this!”.
Mr. Gee Goes Home!
Mr. Gee has garnered some of the most enthusiastic “fans” here on the blog, Facebook and Instagram so I guess I better lead with the star of this week’s title as we grant Mr. Gee his wish, and ours, to finally move into his new home aboard Möbius.
Let’s go back to the big day of Monday August 17th, 2020 when the move began……. Mr. Gee’s “Mom”, aka Captain Christine was on hand to supervise and help out with the big move and the first order of business was to tear down the scaffolding and plastic that we had built around Mr. Gee for the past few months to help keep him clean and be able to extract all the overspray from painting him. Uğur on the Left and Nihat left their aluminium work to help move Mr. Gee from my Workshop up on the first floor and down to the shop floor.
You observant motor heads will notice that Mr. Gee is also now sporting his exhaust, intake and cooling water manifolds and has his massive flywheel all wrapped up inside his flywheel housing where his two hind feet attach. With all this well fed help we were able to wrestle all 1200 Kg/ 2650 Lbs of Mr. Gee onto a sturdy wood pallet and used the pallet jack to push him out the Workshop door onto the balcony. We are fortunate to have access to the big Yellow “praying Mantis” type crane truck which was able to shoe horn his way into a small slot beside the sailboat “Caledonia” which is inside the scaffold tent on the far Right and the smaller paint booth on the Left.
In the center background, Möbius is anxiously awaiting the arrival of her beau Mr. Gee and the big 20m catamaran “Twinity” is in the scaffolded tent on the far Left. Taking our typical “belts & suspenders” approach, we double wrapped Mr. Gee with doubled up yellow webbing and then I added two additional Green/Red Dyneema lines which are many times the breaking strength of the webbing and tied all of that to Mr. Hook on the end of the crane which lifted Mr. Gee like he weighed nothing at all. Captain Christine was filming all this action from the balcony on the opposite side and later told me that her heart was pounding in her throat throughout the whole lift off and could barely film for shaking. Mr. Gee said he shared her concerns as he went over the edge of the balcony but it all went off without a hitch and Mr. Gee was soon flying through the air and heading home. Uğur kept a steady and reassuring hand on Mr. Gee as they moved the crane truck ………… ………. behind Möbius for Mr. Gee’s connecting flight to his final destination inside the Engine Room of Möbius. Unlike E.T., Mr. Gee didn’t need a spaceship, just this equally amazing crane that makes moving equipment like this into tight spaces easy peasy as my Canadian friends might say. It was a complex move as Naval has not yet built the sliding engine lift frame that will be used for any future needs to remove/replace Mr. Gee and his Nogva CPP Gearbox. If you look closely you will see that while the big ER Hatch opens up more than enough space for the total length of Mr. Gee AND the Nogva CPP Gearbox as a single unit, more than half of that hatch opening is underneath the cantilevered aluminium roof that extends out overtop of the Outdoor Galley on the Aft Deck. And just for one more level of difficulty, the ER Hatch is located between the two big Vent Boxes. But these preying Mantis type cranes as I refer to them, was able to do all this in two simple steps.
First lowering Mr. Gee into the aft end of the ER Hatch where we could use the chain block to drop him down further into the ER. And then using its hydraulic extendable arms the crane could slide Mr. Gee forward to the front of the ER. And we then lowered his four anxiously awaiting feet onto the beefy engine beds below. Lots of work remains of course to make all the life support connections for Mr. Gee’s water, fuel, oil, etc., drop in and bolt on the Nogva CPP Gearbox and then align the pair precisely to the flange on the CPP propeller shaft but I am eXtremely delighted to finally be able to say;
Welcome Aboard and HOME Mr. Gee!!
But WAIT!! There’s MORE!!!!
Here is the first Bonus Prize for all of you from Captain Christine who has been hard at work learning her newest video editing software and has put together this short video of Mr. Gee Goes Home.
Hope you enjoyed that and please stay tuned as Captain Christine is just warming up her video editing chops for you.
NOGVA CPP GEARBOX:
For those who might be wondering, we did not attach the Red Nogva CPP Gearbox yet because I’ve been waiting for the spray booth to be available so I can paint him to match Mr. Gee’s Burgundy colour.
So we took advantage of having the crane there to move the Nogva off the Aft Deck and down onto the shop floor by the paint booth. Sadly, this brand new Nogva CPP Gearbox has been sitting onboard Möbius since last November for some reason and so he is pretty filthy from the accumulation of ten months of shipyard detritus and will need a thorough cleaning before I sand and paint him back to new condition and worthy of becoming Mr. Gee’s partner in propulsion of Möbius.
MORE WORK on Mr. Gee
My Workshop/Office at the shipyard certainly feels very empty now but is still a great place for me to continue work on all of Mr. Gee’s peripherals such as the 24V and hand starters, two 250Ah alternators, and the copper/bronze oil & water pipeworks you can see in the back Left here. I have multiple workbenches setup including this sold woodworking bench I built in Germany back in 1983 and still serves me very well.
This week I was able to finish assembling this beautiful bronze and brass engine oil cooler so I can mount that on Mr. Gee’s Starboard/Right side and get it connected to his oil and cooling water lines. It is impossible for me to chose a favorite part of Mr. Gee but this bronze & brass beauty is right up there. As you’ve seen in previous Progress Update posts I’ve been working on this for about a month now and have all the parts fully cleaned, sandblasted and wire wheeled to fully reveal their raw natural beauty. Last week I coated them with two coats of clear polyurethane to keep them looking this way and now have it all assembled. A relatively simple heat exchanger, sea water flows through the rectangular shaped cast bronze housing made from two halves bolted together in the middle as you see here. To better answer the questions I’ve received about how this works, cold Sea Water is pumped into the large copper pipe in the upper Right foreground in the photo above and then out the downward facing 90 degree elbow in the Left background.
Engine oil is pumped in one end and out the other of this 1.5 meter/5 ft long “dimpled” brass tube which lives inside the rectangular bronze housing above with all that cool sea water flowing along its length extracting the heat from the engine oil into the sea water which is then pumped out through the Sea Chest.
The short lengths of copper tubing I’ve soldered onto the edges here are to keep this dimpled tube from sagging in the middle and keeping the water flow even. There is also a sacrificial zinc anode laying in the bottom of the rectangular housing to look after the corrosive action of the slightly dissimilar brass/bronze/copper materials that make up this engine oil cooler/heat exchanger. However I don’t think you need to understand how it works to appreciate the raw beauty of this beast which I can’t wait to show you bolted up to Mr. Gee’s Starboard side and perfectly contrasted with his Burgundy and Aluminium colours so stay tuned for that!
Gentlemen; Start Your Engine; Either Way you Want!
24 Volt Starter
With Mr. Gee now in his new home I have tried to pick up the pace on getting him up and running and for that you need a starter, or TWO in our case of course. First starter is this beast of a 24V SL5 electric starter. It seems to be in very good shape so I just want to take it apart enough to confirm that, give it a thorough clean and lube and replace any parts needed.
Removing the double nuts on the end of the shaft and the four lower through bolts allowed me to pull off this drive end of the starter and check out all the critical components of the drive gear, bushings and clutch. The other housing for the pack of clutch plates affixed to the drive shaft of the starter and the four tabs on the outer circumference of each clutch plate interlocks with the four slots in this outer housing. I learned long ago in my early days of restoring antiques and other engines, the value of taking LOTS of photos as I disassemble things for the first time and this is likely more detail than most of you would like but this is an example of how photos allow me to create my own parts and service manual by showing me clearly what all the parts are, what order and side they are assembled in, etc.. The clutch pack itself resides in the housing of the drive end that you saw me removing above. You can see the four tabs around the outer circumference that engage in the housing above and then the matching set of inner tabs on every other clutch plate. Five sets of clutch plates in all which are mounted on the inner bushing that slides along the brass drive gear you can see one end of inside the drive housing on the far Left. Apologies for the poor focus but this is the whole brass drive gear which has the clutch plates mounted on the top end and the drive gear that engages with the large ring gear on the flywheel when you activate the starter and it turns Mr. Gee on so to speak. For those of you still hanging in there on this deep dive into Mr. Gee’s electric starter, let me show you a good example of why I love and respect these Gardner engines and why Christine and I are quite willing to literally put our lives in Mr. Gee’s hands.
What do you think this grub screw in the outer drive housing is for?
Took me a bit to figure out as well but the little coil spring is a good clue. The light goes on when peering into the inside bore of the bushing and finding that long dark jelly bean shape on the Left is a thick piece of felt.
Aha! This is how you keep the starter’s bearing surfaces of the bronze drive shaft well lubricated with oil! Once a year or so, remove that grub screw, squirt in a few drops of fresh oil and put the screw back in to keep the spring pushing the oil filled felt against the shaft. Brilliant!
But wait!!! There’s more!!! Mr. Gee also has a
The original Gardner 6LXB had this optional HAND CRANK starting system and thanks to the great efforts of Michael Harrison and his staff at Gardner Marine Diesel in Canterbury England they were able to find all these original parts and that box full of Gardner Goodness arrived yesterday! To help you visualise how this hand crank starter system works, this is a photo of a different 6LXB with the hand crank fully assembled. As per the illustration above you can put the crank handle on either end of the engine and given our space constraints at the front we will put Mr. Gee’s hand crank handle on the rear. Unpacking the three boxes from Gardner Marine Spare Parts revealed all these original bits of pure Gardner goodness that I need to build a full hand starting option to Mr. Gee. It is actually going to be quite an engineering challenge that I won’t bore you with any more right now but I am busy designing a way of combining an old and a new version of the Gardner hand crank system that I’ll explain in future posts. This is the chainwheel that goes on the crankshaft and the little spring loaded lever at 2 o’clock engages with a slotted pawl on the crankshaft which the hand crank turns via the chain you see at the top here.
Enough of Gardner starters for now but for suffice it to say that for Christine and I this is an eXtremely important fail safe starting option for us to have on our single engine boat.
Alfa Laval Holding Tank
We were only able to have Cihan for a few hours this week but he was able to add this critical part, which is the waste water storage tank for the Alfa Laval MOB 303 Centrifugal Separator/Clarifier that we have on the Starboard/Right side of the Workshop beside the Day Tank. These Alfa Laval MIB 303’s are found on pretty much all large commercial ships where they are used to fully clean and clarify anything from diesel fuel to engine and hydraulic oils. They are regarded as the ultimate in fuel cleaning for their ability to take the most contaminated fluids and remove pretty much every bit of dirt, water and contaminates in a very short time. Their only downside is that they are very eXpensive but through more of our typical serendipity and good friends we were able to get a slightly used one from a super yacht in St. Martin and now have it installed on Möbius.
The aluminium tank which Cihan mounted this week is the holding tank for all the dirt and water the MIB 303 removes and we just empty it after each use for disposal net time we dock. For those interested in how these centrifugal separators work I will just leave you with the link above and these two illustrations of their basic functional principles. Bottom line for us is that we can turn the dirtiest water filled fuel there is and turn it into crystal clear diesel fuel with NO consumable filters or other elements required. Another eXtremely big deal for us and our remote use cases. Cihan also got started on plumbing our Kabola KB45 diesel boiler/water heater. Copper pipes on the Right side are for the two independent coils of water In/Out of the boiler and the stainless steel pipe above is for the exhaust gasses which connect to an insulated SS exhaust pipe that takes the hot exhaust air out through the hull.
Picking up where we left off last week, Uğur and Nihat finished their work fabricating and mounting the aluminium Antennae Arch and turned things over to the Electrical Team to start wiring this “antennae farm”. This was very much a whole Team effort with Uğur and Nihat looking after all the aluminium work and then Yusuf, Hilmi and Samet doing all the wiring. As you can see all the individual mounts are just tacked in place at this stage enough for us to put each antenna, light, camera, etc. in place and see how well the arrangement worked with regards to all their conflicting requirements and locations relative to each other. Meeting the ideal parameters each one wants in terms of their position, height, distance from each other, orientation, etc. is a classic example of the compromises that go into boat design. I would liken it to managing a birthday party for a group of young children; “I don’t want to sit beside HIM!”, “I want to be her”, “I want to be higher than that one”, etc. But by trying out various combinations we finally settled on this arrangement, starting on the far Left:
AIS antenna for em-Trak Class A AIS
Furuno GPS puck
ACR remote control pan/tilt search light
360 degree OGM 3NM Anchor light on top
225 degree OGM 3NM Steaming Light
MikroTik Groove WiFi antenna
Furuno SC33 Satellite Compass
Airmar 220WX Weather Station
VHF Whip antenna (mostly hidden from view here)
FLIR M332 stabilized Marine Hi-def Thermal camera (night vision)
AIS antenna for Standard Horizon GX6000 VHF radio
With all the positions and heights finalized Uğur welded them all in place, Nihat cleaned up the welds and the Antennae Arch was ready to be taken up onto the Aft Deck to be welded onto the Main Arch. After double checking the exact location where each of the four legs of the Antennae Arch would be welded to the Main Arch, Nihat cut in the large holes on each side where all the cables would pass through and put a nice smooth radius on all the edges. The Antennae Arch we tacked in place and the two teams, Aluminium and Electrical, put their heads together to go over the cable routing and made sure the final location worked out for both the welding, wiring and mounting of each item on the Arch before Uğur welded it all in place. Now each item could be mounted with all the proper gaskets, seals and cabling. While all the items were being physically attached to the Antennae Arch Night cut the bottom cover plates that will seal in the underside area where all the cables pass through on the Main Arch and will then do the same for the Antennae Arch so that both areas stay clean and watertight from the elements. The larger base of the Furuno FAR 1523 Radar gearbox bolts to the platform on top of the Main Arch and when flipped open as you see here, it also houses the first stage electronics for the Radar. The 20m/65ft cable has all the push/lock connectors preinstalled on both ends so it is very large in diameter and quite stiff so it needs to be installed and routed through the Main Arch tubes and all the way down to the Main Helm area.
That housing is all cast aluminium but with the large motor and all the electronics inside it still weighs 27 Kg/ 60 Lbs so Hilmi and the gang got a good workout carefully wrestling it in place on top of the Main Arch and routing the cable. Even something as seemingly simple as these SS through bolts required special care and attention as they use special non grounding grommets with seals so you can not turn the bolts to tighten, only the nuts. But Yusuf, Uğur, Hilmi and Samet working together they soon had the FAR1523 mounted and ready for the 6.5ft open array radiator/antenna to be installed a bit later. Over on the Port/Left side of the Main Arch the Standard Horizon loud hailer and the Wilson 4G wide band omni marine antennae have been mounted on the support strut for the paravane A-Frame and they are now ready to be wired as well. With everything welded and mounted it was now time for Hilmi and Samet to take over and start chasing the miles of wire and cables down through the Arch tubes on either side and then down into their various destinations inside Möbius. This is one set on the Starboard/Right side of the Arch where all the power based wiring goes to keep it well separated from all the data carrying cables which go down the tubes on the Port/Left side of the Arches. The large hinge plates that allow the Main Arch to fold down, created a bit of a challenge as to how to safely and securely route all the cables in both the Up and Down positions of the Main Arch. The idea they settled on was to run the wires as a bundle through this thick rubber hose and fit a fiberglass sealing flange to the upper hinge box. Same kind of setup on the opposite Port/Left side of the Main Arch for all the data cables though it was a bit more challenging as it uses the aft most column which are closest to the hinge pin so a much tighter radius but no match for Hilmi and Samet who soon had it all looking like this. Looking up from the shop floor I took this shot to put it all in better perspective for you as Hilmi and Samet start filling up that rubber hose with its wires and cables and getting it all stuffed inside the Arch tubes.
Trust me, you will be seeing much more of Samet & Hilmi and all the wiring they have yet to do.
Earlier in the week Samet & Hilmi had been busy doing more of the wiring for AC and DC outlets throughout the interior of the boat. They completed all the connections inside this Main DC box down in the Basement where all the high amperage cables, switches, shunts and bus bars connect the four House Battery Banks to their primary loads and distribute the DC power to the forward and aft DC Boxes in the Forepeak and Aft Workshop. For lower amperage 12 and 24 Volt loads I’m using these neat little fused junction boxes throughout the boat, upper one here for 12V and lower for 24V. This pair on the Starboard/Right side of the Workshop are mounted aft of the electrical junction box for the Delfin Watermaker.
You may have noticed in the photo above that they have also now mounted the AC receptacles for 120V and 230V at the bottom Left of the Watermaker box and these too are found throughout each compartment of Möbius. Industrial style light switches are also now starting to appear throughout the non-living spaces such as this one you can see on the bottom Left of the stairs which turns on the LED lights in the ceiling of the Basement.
Just a quick update for you on some of the various interior details which are now showing up such as these Ultra Leather cushions in the Dinette Settee. The lighting does not do justice to the great smoky blue colour Christine picked out for these cushions so you’ll just have to wait until we launch and have proper sunshine coming in through all those windows but you get the idea. Up above the Main Entrance doorway and stairs, Omur has been busy finishing the FastMount panels that go around those walls and ceiling. Looking from the opposite direction when standing in the Entryway Door, Omur is measuring up the panel sizes for that Port/Left side wall panel and you can also see he has the removable L-shaped cover in the upper corner of the overhead Entryway. This cover will soon be upholstered in matching Blue/Green leather and inside will be home to a bunch of electronics such as network switches, Axios video decoder, N2K multi-port blocks and connections for cables going into the SkyBridge Helm Station out of sight on the other side of the Right wall in this photo. Down at the bottom of those stairs in the Corridor Office area, Omur is finishing the installation of those wall panels including the recently snapped in place leather covered panels underneath the marble countertop/ workbench.
Brrrrrrr, it’s Cccccccold inside!
I suspect that most of you can guess what’s going on here?
Correct! The refrigeration company has arrived to look putting in the copper tubing for the remote mounted compressors for the pair of large upright Vitrifrigo door fridges and their matching pair of freezer drawers. While Hilmi and Samet are busy lengthening all the wiring between the Fridge/Freezer units and the compressors, Omur is busy up on the Port side of the Galley putting in the extra 50mm / 2” of insulation that wraps around all 5 sides of each Fridge/Freezer. Meanwhile, down in the Basement the refrigeration guys are busy mounting the four Danfoss compressors to this rack above the coffer dams. Now the insulation wrapped copper lines coming out of each compressor down below, can be carefully routed up through their penetrations in the floor and in through the holes in the back of their respective cabinets …….. ……………….. where they can now be soldered onto the copper lines coming out of each Fridge/Freezer like this. Once soldered together these copper lines are wrapped in new EPDM foam insulation and carefully routed in the area behind each cabinet. Enough extra length of copper tubing will be coiled up behind each unit to allow them to be pulled out in the future for any repairs or maintenance. Here is a quick look in behind the Fridge cabinets to see how the insulated coper lines will be run along the sides and eventually zip tied to the cable trays once everything is all complete and working. The backs of the cabinets will also be sealed to keep them air tight and have marine plywood backs installed.
Can’t wait to show you all these units fully installed next week.
DAVIT ARCH CONSTRUCTION BEGINS:
This stack of CNC aluminium plate showed up this week and can you guess what it will soon become? The subtitle tells part of the story, the upper 20mm / 5/8” plate has all the CNC cut parts for the hinged mounting foundations for the Davit system which will bring the Tender On/Off of the Port/Left side of the Aft Deck and In/out of the water.
FYI; The rest of the CNC cut plates underneath are all the parts for our 5 meter/ 16/4 ft jet drive Tender!
But the Davit goes first and the this recently arrived stack of AL pipe will be used to construct the ladder style double tube Davit Arch. This quick and dirty rendering of the Davit system shows how the overall system will work. There will be two separate Raise/Lower systems both made using Dyneema line on 6:1 Garhauer blocks and clutches going to Lewmar winches. One system will look after Raising/Lowering the Davit Arch itself and the second system will Raise/Lower the Tender from the Arch. This is the only rendering I have time to grab right now and it was from when Yigit and I were first designing and testing the Davit Arch model so much has changed since then such as the orientation of the laddered Davit Arch and the Tender design but it will help show how the Davit moves the Tender On/Off the Aft Deck. The design of this Tender Davit System is the result of a LOT of prior experiences launching and retrieving dinghies and LOTS of thought and experimentation with these 3D models but I am VERY happy with the end result which I believe will be one of the safest, fault tolerant and easiest Davit systems we have ever known. Stay tuned for the real world testing after launch to confirm all this really works!
Nihat and Uğur waste no time getting started and soon have the 50mm / 2” connector/ladder tubes all cut in the background and the extruded aluminium elbows cut at their final angles and chamfered edges for full penetration welding. Our student intern Omer is really learning a lot and enjoying the whole experience of working with us on this new project as Uğur starts prepping the 20mm pieces he has removed from the CNC cut plate that will become the hinged bases for the Davit. I designed the Davit Arch to be three independent parts so it will be easy for Christine and I to disassemble and store on the Aft Deck when we are in Hunkered Down or Canal mode with the whole SkyBridge roof lowered. Simply done by putting in these double Blue 20mm joiner plated which will be bolted together. Nihat has tacked two of those joiner plates together to keep make it easy to cut them to shape and now drill out the six bolt holes in each pair of joiner plates. And he soon has all four joiner plates and the other hinge plates all drilled and edges radiused or chamfered for welding. Simple yet very strong and effective construction allows Uğur to quickly tack up these two vertical legs of the Davit Arch. KISS design continues with simple slots cut into the bottoms of each Davit Arch pipe where the hinge plates will be inserted and welded. Like this. Flipping the vertical legs upside down atop their joiner plates …. …… makes it easy to align them and tack them in place. And the two vertical legs are all tacked up and checked for alignment and ready for final welding. Uğur begins the fabrication of the horizontal upper beam by laying out the angle where the elbows connect the angled 90mm / 3.5” pipes to the upper ladder beam. Fabrication of this Upper Beam goes quickly with the KISS design.
Note that Uğur has inserted short lengths of inner reinforcing pipe to strengthen the joint between the angled pipes and the elbows. Which end up looking like this. And does the same thing at the other end of the short angled connecting pipes of the Upper Beam. The fully assembled Davit Arch can now be tacked together. Bottoms of the Arch pipes are closed off. And now the whole assembly can be checked for perfect alignment and square and ready to be fully welded up and taken up to the Aft Deck next week. And that’s another week gone by and hopefully another week closer to launching XPM78-01 Möbius.
Captain Christine has two more Bonus Gifts for all of you but I’m going to keep you waiting just a wee bit longer for those to post but I think you’ll agree that they are worth the wait.
In the meantime, I hope you enjoyed this week’s XPM78-01 Möbius Progress Update and if you did or didn’t please let me know one way or the other and add any other comments or questions in the “Join the Discussion” box below.
Wow! Surely my calendar is fooling me; December already? Another year winding down to a close? Where does the time go??!? I’ve long been fascinated by the dichotomy of how our sense of time past works where the same amount of time can seem to simultaneously much longer and much shorter. In the case of Möbius it seems like both yesterday and a lifetime ago when we first started this crazy idea of switching from sail to power for our future voyaging. Then we dove head first into the deep end of the crazy pool by deciding to design and build it from scratch and started this wild adventure we are now on.
Here are just a few examples of the kind of mental dichotomy that fascinates me; Last month we passed our two year anniversary of being here in Antalya, 612 days ago (April 6, 2018) the first shipment of aluminium CNC cut plate arrived and construction of the hull began and in a few days (Dec. 19, 2018) it will have been one year since we signed on with with Naval Yachts to build the fully finished boat with them and have it be the first “prototype” of their new line of eXtreme eXploration Passage Maker XPM boats. How is it possible that SO much has happened in SO little time?
Well, not to waste any more time, I will ponder and wonder that question for a long time to come but for now let’s get on with catching up on all the progress Team Möbius has made this past week of December 2-6, 2019.
Let’s start this week’s update with the electrical wiring. The cables referenced in this week’s title include these four black and red eXtreme beauties which carry the eXtremely high amp 24 volt current from the 1350A @24V house battery bank to the fore and aft DC distribution panels. As per their labeling, each of these cables is 120 mm2 which would equate to about half way between the American Wire Gauge or AWG of about 4.5/0000. By any measure these are huge and we are doubling these, two positive and two negative so that each pair carries half the amps. Why such eXtreme sizes? In short, Electrical efficiency such that we keep the voltage loss occurring on these long cable runs as low as possible, meaning that as much of the current that leaves the batteries arrives at the consumers on the other end. Our standard maximum voltage drop for all DC circuits is < 3% and for the main supply cables such as these, we keep it under 2% and hence the large cable size. Last week Hilmi ran the four cables from the Basement up to the Forepeak using the cable trays you see in the photos above and this week he ran the other set of cables up from the basement and along the cable trays under the side deck space flanking the SuperSalon you are seeing here and running back to the Aft DC Distribution Panel in the Workshop. Down in the Basement where the House Battery Banks are located we find this growing collection of different cables which now includes the four 120 mm2 Red/Black cables. We had ordered the negative cable in Yellow which is the preferred new ABYC standard to help differentiate the DC negative from Black AC wires but this large size cable is difficult to find and the Yellow jacketed version wasn’t available for several months so we went with Black and will add extra labels along each cable run to maintain clarity. Not that anyone would likely confuse these huge cables for anything but high amp DC, but you can never be too careful when it comes to all things electric.
The two House Battery Bank bays which as you can see here are integral parts of the framing of the hull straddling the 25mm / 1” thick Keel Bar which is what the floors of these two bays are setting upon. Nihat has been welding in the side framing which will hold the composite containment boxes in place and bolting these floors to the hull. Even though all our batteries are fully sealed AGM type batteries with no actual fluid in them, we are building composite containment boxes to add an eXtra layer of safety to cover any possibility of a leak in one of the batteries. The L-bar frames hold the base of the batteries in place and then there will be a separate frame that wraps around the tops of the batteries and clamps them down to the hull so they can not move even in the unlikely event of a full 360 degree roll.
Uğur and Nihat continued their work on fabricating the framing for the glass and acrylic windows up in the SkyBridge. They have all the L-bar tacked in place that will provide the frames for gluing in the lower glass “eyebrow” windows and then started to weld in the flat bar on top to create the window ledges for the upper removable acrylic sheet windows.
Note the large vent seen in the foreground here. This will have a large mist elimination grill in front of it before all the fresh breezes flow down into overhead diffusers in the SuperSalon.
The front three 380W solar panels attach to a frame which sets just inside the upper angled edge of the space in front of this vent opening and hinges along the upper edge of the vent frame. This hinged frame of solar panels allows us to lower its front edge down onto the aluminium roof panel and seal off this space when we are on passages and then unclip it and raise it to its horizontal position which creates a huge wind tunnel to capture all the breezes coming from the bow when we are at anchor and funnel them all to this big vent and down into the SuperSalon. The flat bar window sills were slot welded to the tops of the L-Bar glass window frames and then ground flush and invisible. The angled support you see on the far right here is the articulated support post that is put in place when the roof needs to be folded down into either Cyclone or Canal mode. Most of the time it is removed and stored in Workshop. The front four support posts for the roof are attached with these bolt on flanges so they can be removed prior to folding down the roof. Same bolt on flanges are mounted vertically where these four posts attach to the the roof frame.
Both of the Cabinetry teams continued to make great progress on their respective cabinetry work for the Galley and the Guest Cabin areas so let’s go check in with them.
The spacious SuperSalon is difficult to capture well with photos but perhaps these two panorama shots will help. This one shot standing in very front where the Helm Chair will be looking Aft.
Click to enlarge any photo. Shot standing on the stairs up to the Aft Deck looking forward. Obviously very distorted views but when combined with the regular photos I hope it helps you visualise this truly Super space. Switching back to normal photo mode AND sparing no expense we have brought Chef Christine aboard to inspect her rapidly evolving Galley. Testing out a simulated pot stirring position where the induction cook top will soon be installed, the Chef seems to approve. Omur and Selim spent much of the week painstakingly fitting the Gull Wing door Garages into the Galley cabinets. With mitred corners and being recessed into the countertops requires very exacting dimensions along all three X,Y and Z axis in order for it all to work and for these Garages to be able to slide into their final position. And when they do, it looks abfab!
For those wondering, the Garages are “floating” above the countertops to allow for the 20mm/ 3/4” thick granite countertops. eXacting is what Naval’s Cabinetmakers eXcel at and here is another example as Omur (left) and Selim try out different sheets from the flitches of Rosewood we’ve purchased. When the thin sheets are sliced off the solid slab of Rosewood they are laid together in in the sequence as they come off so each sheet is different but matched with the one before and after. Omur has brought a series of these sheets onboard and is now trying out each one to find the Goldilocks match with the sheet on the right which forms the back of the dining settee. Selim and Omur also fitted the armrest end of the dining Settee. The top will be padded and upholstered and there will be a door in the Rosewood outer side to provide access to one of the electrical panels that will be housed inside.
LOTS of storage space below and behind the seats as you can see. Opposite the Settee on the far right here, Selim has removed the top of the cabinet for the two side by side freezer drawers and taken it back to the Cabinetry Workshop. Once he has these solid edges attached and trimmed flush, he will take it over to the big veneer press and apply the veneer sheets he and Omur have so carefully chosen. Over on the other side of the Cabinetry Workshop, Omer, perfectly framed by this cut out in the wall panel that goes on the outboard side of the stairs leading down into the Master Cabin, has been making great progress on the complex little cabinet for the sink in the Guest Head/Bathroom.
We’ve made quite a few changes to this early rendering of the Guest Head and my apologies for not having an updated render to show you but if you do a mirror flip of this render in your head (sorry) you’ll be close to the new layout. Omer is demonstrating how the countertop with the sink setting atop the right end will appear to float above the cabinet below and if your mental gymnastics worked well, the image in your head should augment the reality you’re seeing here. Earlier in the week it looked like this with the sink area on the left and the L-shaped that runs down the side of the Head and then wraps around to create a handy shelf behind the VacuFlush toilet similar to what you can see in the original render above. A good example of how the solid Rosewood is glued up to create the large radius corners and the sink surround edges. Which soon looks like this as Omer turns his attention to the veneer he has chosen for the wrap around countertops. He has also fabricated these two large radius corner posts for the cabinet below the sink. Which he is gluing up here. Closeup of those large radius corner posts now glued with reinforcing biscuits into the completed under sink cabinet. Here is how the countertop and sink cabinet will fit together.
Mr. Geeeeee gets a Beautiful New Mechanic!
Mr. Gee as we affectionately call our mighty Gardner 6LXB engine has also been getting some much needed time and attention the past few weeks so let’s catch you up on that. Since she returned from her short sojourn in Spain two weeks ago, Captain Christine has added new title to her already long list by becoming Mr. Gee’s new mechanic! With Commodore Barney thankfully supervising very closely. Currently Mr. Gee more closely resembles Humpty Dumpty as he is all in pieces again after being put together briefly for a complete sandblasting of all his external parts. Now we are busy cleaning up all the internal parts which have accumulated over the 50 years of his previous life in powering a tugboat on the Thames River in England. Christine has these valve lifter assemblies all cleaned up and ready for their new life as the heartbeat in Möbius. Looking back a few weeks, this is what Mr. Gee looked like after giving him a very thorough sandblasting and several coats of high temperature silicone based primer.
Ruby the Wonderdog on the left and Barney the Yorkshire Terror always on duty supervising every step of the way. Loosing his head, two cast iron ones in fact, each of which must weigh at least 70kg/150lbs, next up for removal is the cast iron cylinder block sitting on top here. I had previously removed the old cylinder liners and had new ones pressed in and machined to finished size so they are all ready for their equally new pistons and rings.
One of the great things about these Gardner engines and what makes them surprisingly viable for reuse is that while complete engines are no longer being manufactured almost every part is still being made and available from Gardner Marine Diesel which carries on the Gardner name and heartbeat. So with the exception of the primary castings such as the cylinder block, crankcase, and crankshaft I was able to buy every other part new from pistons and rings, to every bearing, every gasket, fuel injectors, etc. Once Christine and I have him fully scrubbed clean we begin to put Humpty Dumpty back together again and bring Mr. Gee back to his original glory or better.
I have Mr. Gee fully disassembled for about the fourth and hopefully final time since I first picked him up in England two years ago. Here he is stripped down to just his all cast aluminium crankcase. Next week I’ll take him outside for a thorough de-greasing and pressure washing to flush out every nook and cranny to get rid of all the accumulated oil sludge and the sandblasting sand that has crept inside.
Yesterday I tackled the truly massive crankshaft by scrubbing every surface and all the internal oil galleries with degreasing liquid and LOTS of paper towels. Old on the right, partially cleaned on the left. About 3/4 clean now before getting a good pressure wash and some new fibre discs in the torsional damper on the left end.
Visible below the crankshaft is the Cast Iron cylinder block with its new liners and ready for its equally thorough cleaning and prep for reassembly. Old meets new!
The shiny new aluminium ring I’m holding in front of Mr. Gee’s massive marine flywheel is the outer Centamax ring that transfers Mr. Gee’s rotational torque of the spinning flywheel to the Nogva CPP input shaft. Easy to see how simple this Centamax flex coupling is with the outer aluminium ring’s fingers fitting tightly into the matching grooves in the thick rubber disc bolted to the Nogva’s input shaft. The grey cast aluminum housing on the left is off Mr. Gee and mates perfectly to the the matching SAE bolt pattern on the red Nogva servo box. Fortunately for me, the Society of Automotive Engineers or SAE began creating standards for things such as threads and bolt hole patterns back in 1905 and are still being used to this day quite universally and ubiquitously in the manufacturing world globally. Gardner and Sons Ltd. was founded in 1868 and began building engines in 1895 and so they were amongst the very first to adopt SAE standards for their engines. Sound boring? Well not to me! Our union of old and new provides a great example of why such standards matter an enable me to simply bolt our almost 50 year old Gardner 6LXB engine to our brand new Nogva CPP using in this case the SAE14 bolt hole pattern to fasten the new Nogva/Centamax ring to the Gardner’s flywheel. Michael Harrison now runs Gardner Marine Diesel after his Dad retired after working for Gardner and Sons Ltd for most of his working life and then started Gardner Marine Diesel when he bought the entire inventory and much of the machinery when Gardner and Sons closed shop in the early 1990’s. Michael not only found Mr. Gee for us when he was being removed from that tugboat so they could upgrade the tug to the more powerful 8LXB for the tugs newly upgraded job requirements, but he also found this original solid steel marine flywheel “blank”. Next week this flywheel will be machined with the SAE14 bolt pattern on this outer face so I can bolt the Nogva/Centamax ring to it prior to mating the Gardner with the Nogva and lifting them into their new home in Möbius’ Engine Room for the first time. Just a wee bit eXcited about that and so stay tuned for more in the coming Weekly Progress Updates.
But WAIT! There’s more!
NEW ARRIVALS @ Naval Yachts
Remember that crate Christine & I built when we were back in Florida last month? and then filled with the many, many, many parts which we had been ordering and sending to our Florida addresses? And then trucked down to Miami to have it air freighted over to Naval Yachts?
Well, it showed up here on Friday! We’ll have great fun unpacking it and showing you all the contents next week.
But WAIT there’s even mooooooooooore!!!
Look what else showed up on Friday!!
Can you guess what’s inside THIS crate and why our brilliant interior designer Yesim is almost as excited as we are about it? This should help you guess? Do Hakan and Yesim help you get your guesses warmer? Or a peek inside perhaps? Good Guess!! It is our eXquisite Galley countertops which have all be cut from this slab of Turquoise granite at Stoneline. It arrived at the end of the day on Friday so we only had time for a quick inspection and we’ll show you much more as it gets installed in the coming weeks. But we were able to see the bullnose rounded edges and some of the other details and can’t wait to inspect it fully tomorrow. and I promise it is the LAST time for this week but ……………………………………
WAIT! There is just ONE more HUGEY thing to show you………………………………
Christine and I regard ourselves as two of the most fortunate people on the planet because we are surrounded by the most awemazing friends who, in addition to being very good friends, also have talents you just wouldn’t believe. One of dearest friends and most talented artists we know is pictured below, the one and only Sherry Cooper.
Sherry and I first met back in 1981 when she and her husband Rick arrived in Baden Baden Germany where I was living at the time. I was a High School teacher for the Canadian Air Force jet fighter base there and Rick joined us from his English teaching gig in Vancouver BC. In addition to teaching there for the next three years we all traveled extensively throughout Europe, Africa and beyond and our friendship continued to grow ever since.
And I am I telling you this because??
Because Sherry agreed to put her incredible artistic talents to work and design the patterns for those two plate glass walls that form the corner of our Master Cabin shower that you may recall seeing in some of the early renderings of the Master Cabin.
Plain clear glass just wouldn’t fit with the eXtreme beauty aboard Möbius now would it? Plus, unlike me, Christine has a modicum of privacy and wasn’t thrilled by the idea of being on such a well lit stage when she was showering. So we came up with the idea of having the glass etched with some fun and beautiful pattern. But where would we find such a pattern?
Ha! Easy peasy as some of my Canadian friends might say, we mentioned it to Sherry on one of our visits and she delighted us by jumping at the chance to be so involved with the creation of our new home. Several meetings and lots of Emails later we evolved the idea of having a theme that would involve some of the art and imagery of the Aboriginal Peoples of Möbius’ Home Port of Victoria BC. The term “Aboriginal” refers to the first inhabitants of Canada, and includes First Nations, Inuit, and Métis peoples. This term came into popular usage in Canadian contexts after 1982, when Section 35 of the Canadian Constitution defined the term as such.
Then we asked Sherry if it might be possible to incorporate some pictures we so vividly recalled from her prodigious photography work of some otherworldly reflective waters where she and Rick have their boat near Gambier Island? Of course she said!
My apologies to you Sherry for this amateurish picture of your pictures, but really people, can you believe that these are untouched photos Sherry took when she spotted these patterns being reflected in the water as Rick was docking their boat??!!!
So what did Sherry come up with?
Check out what we awoke to find in our Email inbox this morning!
We will now be having one of these images etched into each of the two plate glass shower walls and can’t wait to show you the results when they are done and installed in the Master Cabin.
You are AWEMAZING Sherry! Thanks and just let us know when you are flying over to come see your work on display inside Möbius!
OK, as promised that is finally it for this week’s update. See what I mean about that conundrum of time? How could so much happen in so little time? But it did and I have the photos above to prove it!
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Thanks so much for taking the time to join us on this week’s adventure and PLEASE do be encouraged to add your questions, comments and suggestions in the “Join the Discussion” box below.
This was a four day work week here in Antalya as Monday was a national holiday so a few less hours this week but I’ve still got LOTS of new things to show you as our brilliant interior designer Yeşim created more renderings of her designs for the Guest Cabin and Christine’s Office.
Christine and I took advantage of the long weekend to take some dear fellow sailing friends who were staying with us for the week from their current home in Barcelona, out to see one of our favorite summer spots in this area, Köprülü Kanyon. I will let the following few photos show you why:
Less than 2 hour drive from our apartment and the shipyard takes you up this fabulous river canyon to this ancient bridge built before Roman times and while narrow is plenty strong to drive across. Here was our view of that same bridge from down on the water in our inflatable river raft paddles at the ready.
Not quite what most people picture when they think of Turkey. Our excellent and very strong guide Baris, literally pulled us UPSTREAM against this current by scrambling along those vertical stone walls on the left with a rope from the raft in his teeth! Sure glad he did as this is what was one of several waterfalls literally coming out the sides of the canyon walls as we travelled upstream. We stopped along the way to enjoy one of our many favorite Turkish delights, Gözleme!.
Thanks for such a great visit Annabelle, Sophie and Maurice!!
Tuesday it was back to work for all of us so let’s jump right in by looking at what’s been new this week onboard the good ship Möbius.
Can you guess what these three are working on? There is a similar smaller one leaning up against the wall of the SuperSalon if that helps? Aha! It is upside down and on the floor in the first picture and now we see that this is the plate with all the vent ducts that direct the fresh air flowing into that huge air vent formed by the hinged solar panels up on the front angled edge of the roof overhead. With this plate removed you can see how it closes off this space above to create a nice plenum that creates a bit of a high pressure area as the breezes funnel their way into this smaller space and is then forced out through each of those five 100mm / 4” vent ducts.
The smaller plate closes off the plenum at the very front overtop the Helm station and chair. I’ve created he following quick renderings to help show how these two natural vent systems work. The largest volume of air into the SuperSalon will come in while we are at anchor through a vent funnel that is formed by these three blue solar panels shown here in closed/passage making position. All 3 panels fit into a single large frame which is hinged at the top/aft edge where it meets the short glass panels at the front of the SkyBridge. Removing this frame of solar panels you can see the large green mist eliminator vent. Now imagine the frame of solar panels being propped up about 300mm/12” at the front edge by the red handrail and you see how the opening this forms is a perfect tunnel that captures any breeze coming over the bow when we are anchored and funnels it back through the green demister grill vent and down into that larger plenum you see being built in the photos above. Dropping the rendering camera down to foredeck level and looking up under the overhang of the Pilot House roof you can see the series of red slots which similarly funnel the air in the high pressure zone of air trapped in that upper corner between the negatively raked front glass and the roof overhang. This air runs through another mist eliminator grill on the inside and then fills up the forward plenum above Uğur’s head as he preps this plenum for the 2nd smaller plate to be bolted in place.
Nihat is drilling and tapping the holes for the countersunk SS bolts which will secure and seal the aft plate to the ceiling. The individual vent tubes extend up into the plenum about 150mm / 6” and will have adjustable lids on their tops to close off the vent pipes completely if needed and they also work similar to the Dorade Vents you’ve seen in previous postings to prevent any water that might make its way in here from getting into the SuperSalon and instead being drained off to the outside.
This shot borrowed from the Imperial diffuser company web site shows how this will be finished off nicely inside the SuperSalon. The upper part of the PVC diffuser fits inside the aluminium vent pipe, the upholstered ceiling panels is snapped into the ceiling grid and then the bottom half of the PVC diffuser click/snaps in place. The air flow volume and direction of air entering through each of these diffusers can be adjusted by turning the center disc. This allows us to easily increase or decrease the amount of air flowing in and ensures that there is never a blast of air coming straight down on your head. Moving forward into our Master Cabin Cihan has been busy installing these hoses that carry away any water that collects in the gutter around the deck hatches and drains it off to the side and out a pipe welded through the hull just below the Rub Rails. Up above on deck Mehmet with Sezgin below, is checking these hatch gutter drains for any leaks by filling them with water from that white can. Down in the Basement Cihan has now got the water lines for the four large potable water tanks below the floor in the Master Cabin routed through the Basement on their way to the main potable water manifold in the aft Workshop where the water maker and house pressure water pumps are also located. You can see how well these perforated aluminium trays work to keep each hose and wire fully supported and neatly organised, just like they do for all the wires and cables.
The two black and red diaphragm pumps in the background are some of the series of low water bilge pumps that suck up any moisture that might gather in the gutters created by the angled margin plates that connect the tank tops to the sides of the hull plates and thus run down all sides of each interior compartment.
OK, that covers what’s new this week on Möbius in the very real worlds of all the aluminium, hoses, wires and ducting, now let’s go get virtual with Yeşim as she generates some renderings of the initial interior design work she and Christine have been doing for the aft Guest Cabin which also doubles as Christine’s Office.
First for orientation, here is the 2D General Arrangement or “GA” drawing of Möbius showing the area we are focusing on now. This profile drawing will let you see how the upper level of the SuperSalon relates to the Master Cabin in front and the Guest Cabin aft. In the previous progress update post “Shhhh Here is an Early Sneak Peek of the Interior of Mobius” you saw some of the very first renderings of the Guest Cabin and here is the next round which now includes renders of the shower, head/bathroom and my little office workbench area in the corridor outside the Guest Cabin.
For this rendering we have descended the stairs from the SuperSalon, walked to the end of the corridor leading to the WT door into the Engine Room and Workshop and turned around in the Workshop doorway to see this workbench/desk running along the Port/Left side of the hull. This will be my little office and more so my “clean” workbench area for things like my 3D printer, electronics work and so on and I am more than just a little bit eXcited when I imagine working here.
The cabinets down the left side of the stairs will be where the aft electrical distribution panel will go and the door on the right opens into the aft Head/WC. To get this rendering the shower where the camera would now be sitting has been removed. To see that shower let’s move forward and step into the Head doorway and turn around to look aft down the corridor to that WT Workshop door you see the aft end of my workbench on the right. With the large 700mm / 28” hatch overhead you can almost feel the fresh air and sun inviting you into this beautiful shower. Important to keep our guest fresh, clean and happy right?! Walk into the shower and turn around 180 and you get to see the equally beautiful Guest Head/Bathroom. We’ve been working more on getting this important space just right this weekend and we will show you the latest changes next week. Completing the tour of this corridor area let’s get rid of my workbench/office and step back into that space to look across the corridor into the entryway into the Guest Cabin. Doors into the Head is on the left and shower on the right, WT door into the ER/Workshop on the far right. Stairs on the left lead up to the SuperSalon and then turn 180 to go up the next flight to the Aft Deck.
Our Horizon Line Handhold continues throughout all these spaces as you can see to ensure there is always a secure hand hold at all times for all heights of people and continues our theme of wood/earth below the Horizon Line with clouds and sky above. Cutting out the corridor wall above allows us to see the layout of the Head and Shower areas on either side of the entryway into the Guest Cabin. Stepping into that doorway above with our very wide angle lens shows us the basic layout of the Guest Cabin with the fold down Queen bed/couch at the far end and fold down Pullman berth above. Christine’s desk and bookshelves on the right with more on the upper left. Removing Christine’s desk let’s us get this shot looking forward on the boat to the see the bookshelves and closet. Doing the same trick from the other side let’s us look aft and get this full shot of Christine’s desk and work area with the two big hatches overhead. And we complete our tour of the Guest Cabin by momentarily deleting the couch/bed and looking across to the entryway door with the Shower to the left and Head to the right. We have actually gotten rid of this door and instead will have the door on the Head also serve double duty as the door to close off the entryway into the Guest Cabin.
These “two in one” doors are great examples of how we often use elimination as a design tool to create better solutions and KISS or Keep It Safe & Simple designs. In this case instead of up to four doors in this one area we have just two which is so much more efficient use of space and a more effective design.
That’s a wrap for the week that was July 16 to 19, 2019 here at Naval Yachts and we’ll see you again next week to bring you up to speed in the next run of this awemazing adventure we are on.
Thanks for joining us and PLEASE be sure to add your questions, comments and ideas in the “Join the Discussion” box below.
This week’s progress building our beloved MV (Motor Vessel) Möbius and XPM78-01 here at Naval Yachts reached another exciting milestone with the cutting of the first wood being used to build our interior cabinetry and furniture. We are VERY excited about this and as per the title we think “You Wood Too!” Not that the work on all things metal and mechanical aren’t exciting as they continue to progress very well too, but this most recent deep dive into designing and now starting to build the interior of our new home and boat has us particularly excited and wanting to share it with you so please join us as we dive into the latest progress in designing and building mv Möbius.
As you may recall if you read the previous post “Miss Mobius World Wood Pageant” we have chosen to use Rosewood for all our interior woodwork and so it was a very exciting day when the first truckload of solid and veneer arrived from the lumberyard near Istanbul. With different languages and species all this wood is from the Dalbergia family and goes by several names including Santos, Palisander, Pelesenk, African/Burmese Blackwood and (your choice) Madagascar/Brazilian/Indian/Honduran/Yucatan/Amazon/Burmese Rosewood. You may be interested to know that these woods are called Rosewood because they give off a rose like scent when being cut and worked so I will borrow from the bard’s astute observation that “A rose by any other name would smell as sweet”, add my own “and be as beautiful” and from here on in I will simply refer to this as Rosewood.
The photo above was taken as the protective wrap was first pulled back to unveil the stacks of hundreds of flitches of Rosewood veneer quickly followed by the same reveal of these planks of our solid Rosewood. While we had spent a LOT of time searching for and choosing this wood it still took our breath away with the reality and beauty of this wildly varied colours and swirling grain patterns.
Christine and I were still in Florida being Gramma and Grampa so Dincer had flew up to Istanbul to personally select the specific batches of veneer and solid Rosewood for us and as usual he did a masterful job of choosing the just right Rosewood for us.
My dear friend Eileen Clegg once called me an “extremophile” which I took as a compliment, and with Möbius being the first of Naval’s XPM eXtreme eXpedition Passage Maker series of boats it seemed only fitting that we would have sought out a wood with such eXtreme ranges of colour and grain. The only thing more eXtreme than the beauty of Rosewood is its price but Christine and I may well spend the rest of our lives living aboard Möbius and want to be surrounded by beauty every one of those days so this was an easy decision to make given the infinite amount of joy it will provide for us and others who join us aboard.
This photo shows how the cabinetmakers have unpacked the first four of that stack of wide strips of veneer known as flitches shown above into matching layers after cutting off any splits or damage at their ends.
Is this Beauty in the eXtreme or what??? As with most other facets of boat building Naval does all their cabinetmaking in house which includes doing all their plywood lamination so these Rosewood flitches will soon be matched up on either side of marine birch plywood and be pressed and heated in this large hydraulic laminating press to create the finished veneer panels. You will see this fabulous bit of kit in action in the upcoming weekly updates. As beautiful as the veneer is the solid Rosewood more than shared the spotlight as you can see here with these first four 25mm / 1” planks to emerge from their own stacks off the truck.
The very large staff of professional cabinetmakers, which I will be introducing to you over the coming weeks, seemed to be equally as excited and impressed by the opportunity to start transforming this Rosewood into furniture and cabinets for Möbius.
You Wood too right? Those first planks were soon coming out of the table saw and shaper as these T shaped strips which will next be glued to all exposed edges of the veneered panels. This solid Rosewood edging is at least a 10mm / 3/8” thick which enables further shaping and ensures that none of the veneer edges are exposed to any wear and tear over the years. Panels which will have all four sides exposed when finished on things like drawer fronts have these solid Rosewood T’s glued on all four edges with mitred corners such as the one on the far left here. All the outer corners of these T edges will be rounded over with a 3-5mm radius to make them very easy on your hands and very luxurious in their looks. Another technique for creating the large 50mm/2” Radius external corners and reducing the amount of Rosewood required on things like vertical cabinet edges, corners of the bed frame, etc. begins with gluing these triangular shaped lengths of solid Beech, the white wood here, to lengths of solid Rosewood. Why? might be a common question so I grabbed a piece of scrap wood with a 50mm Radius on the bottom side and made that horizontal pencil line to show how the Rosewood portion of the glued up piece on the bottom left will be machined with that large radius surface being all Rosewood and the inner triangle of Beech providing the a large surface area for the adjoining panels to be glued in place and be hidden in the joinery on the inside. Once the glue has cured the next day and operation is to machine these laminated lengths of Rosewood and Beech ……. …… into this shape and you can now hopefully see how this creates the two wide flats at 90 degrees to each other to form the large vertical corners on cabinets and corners and then have the full 25-30mm thickness of Rosewood to form the rounded outer corner.
I’ll be able to show you this in much more detail in the coming weeks as the cabinetry progressed so let’s leave the cabinetmakers alone for a bit and go back aboard Möbius to see how things are progressing there.
The “Sparkies” as our brilliant Kiwi (New Zealand) designer Dennis would call the team of electricians who are growing in number aboard Möbius, are now busy running literally nautical miles of wiring throughout the conduits and wire trays and have setup shop in the SuperSalon to do the cutting and labeling of all the individual runs of wire. If you look in the background of the picture above (click to enlarge any photo) or in this close up shot you can see some of the runs of flexible conduit going up the inside of the vertical SuperSalon window mullions which are soon filled up with the wires for devices up in the ceiling of the SuperSalon and the SkyBridge. Each length of wire is labeled with the temporary tubular yellow labels you see here. With hundreds, perhaps thousands of wire end connections to make, this labeling is key to making it faster and clearer for the Sparkies to know that the right wire is going to the right switch, light or circuit breaker. Before the final wiring of each connection is done each wire will be cut to the just right length and additional labels will be heat shrunk to each end of all wires for future reference whenever someone, aka ME! is doing any modifications or maintenance of any of the eXtensive electrical systems aboard Möbius.
Down in the Basement we see that the “Poopsmiths’ ** aka plumbers in Kiwi speak, have been busy starting to install the runs of Vetus Sanitary hose for all the Grey (shower & sink) Water and Black (toilets) Water tanks, pumps, drains, etc.
** Full list of such wonderful Kiwi slang words here for those of you interested in “dropping your gear’ and go “full tit” to be fully “home and hosed” when it comes to speaking like a native down under. I hope this doesn’t’ come across as rarking you up or pack a sad for too many of you and if so the next drink is my shout but this offer is only good at sparrow fart.
Those of you who have been following this blog for awhile will recognise this and for the rest of you this is one of the hatches which I’ve designed and Naval is is now building in house. The little army of aluminium boxes on the right are the hinge boxes which provide the support for the SS hinge pins that slide through the 8mm / 5/16” holes in their sides.
Turning these boxes transparent in the 3D model of these hatches (click to enlarge) will show you better how they work. Everything but the Rosewood inner liner is all aluminium but I have coloured the Lid Blue and the Frame in Red he blue for added clarity and you can see how the Blue Hinge Arms which are welded to the Lid, extends into the Hinge Boxes under the deck and rotate on the white SS 8mm diameter hinge pins. I used one of my favorite CAD tools, Autodesk Fusion 360 to design these hatches and here is a little animation Fusion enables me to create which I hope will show you how the hatch works.
One of the most rewarding aspects of designing and building your own stuff is when your designs are transformed into reality and here is my most recent example. This is what the Hinge Arm you’ve seen above looks like as a component within the Fusion 360 model. And here I am holding that very same Hinge Arm after Uğur has cut it from a solid block of aluminium. We decided to create a few prototypes of these hatches to fully test out my design in the real world and here is one of the prototype assemblies of the Hinge Arm assembled within the Hinge Box on a temporary threaded hinge pin. Hinge Arms tacked to the Lid and Hinge Boxes tacked to the outer Frame. A quiet ”Open Sésame” and Voila! it works! The hatch opens fully to the 120 degree angle I wanted as the Hinge Arms come into contact with the inner edge of the cut-out in the outer Frame where the Hinge Boxes attach.
After a few tweaks with the prototype hatches to get these hinges working and positioned just right we were ready for the critical step of welding the Hinge Boxes to the actual Hatch Frames that have been welded into the decks on Möbius.
As you can see from the photos and models above, the two Hinge Pins have to have their centerlines precisely aligned in order for the Lid to open smoothly so Yiğit and I designed up a jig that Uğur and Nihat could use to hold each pair of Hinge Boxes in just the right position under the deck plates and up tight against the outer Frame surfaces and tack the Hinge Boxes in place. You can see the aluminium plate part of this positioning jig in Ugur’s right hand here and It worked just as we hoped. I forgot to take a picture of the jig itself so what you can’t see but can hopefully imagine is that there are two arms welded to the edge of that aluminium plate which exactly replicate the Hinge Arm positions and have matching pipes for the Hinge Pins to go through. So Uğur slides these two arms on the jig into the rectangular openings you saw above in the outer Hatch Frame and then holds each Hinge Box in his left hand and slides it over the arms of the jig and inserts an 8mm pin through the holes in the Hatch Box and the jig.
Takes longer for me to type this than it did for Uğur and Nihat to tack the Hinge Boxes in place and hope this all makes some sense to most of you?
While Uğur and Nihat were busy working up on deck, our awesome Master Welder Sezgin was busy down on the shop floor under Möbius finishing up the welding of the Hatch Lids. And the pile of finish welded Lids piled up quickly. In case you are wondering, he tacked two lids together to help hold each Hatch Lid assembly in alignment and prevent them from warping or moving as they were welded up. Then the tacks are ground off to separate each Lid and the Lids are cleaned up and prepped for the last bit of welding the Hinge Arms to the Lids which is perhaps the trickiest and most important step to ensuring that the Hatches open, shut and seal just right. Once the Lids have their Hinge Arms welded on they will be sent off to the glass supplier to cut and install the 15mm tempered glass to complete the Lids and I’ll cover that as it happens in the next few weeks.
And as Porky the Pig used to say “Th-th-th-th That’s All Folks!” At least for this week. Hope you are continuing to enjoy and possibly even get some value from these weekly progress updates and I look forward to your comments, questions and suggestions you leave in the “Join the Discussion” box below.