Damit, that’s a mighty fine Davit! Progress Update Sept. 21-25, 2020

Starting with the biggest news first; Christine and I took a much needed “mental health day” by renting a car and driving up the coast for an overnight getaway in a lovely little area we’ve been to before that is only an hour’s drive from our apartment in Antalya.  We’ve been working non-stop seven days a week for the past six months and thought it would be smart to take a brief break from boat building. 


antalya-province map of overnight getaway Sept 26 2020We are very fortunate that the Antalya Free Zone and our apartment are at the very far West end of the city of Antalya that stretches over 30km along the long crescent shaped coastline of the Gulf of Antalya you see here.  The mountains rise up around us less than 1km from the beach and we only drive about 2km SW to put us on a fabulous coastal road along the tree lined rocky coast.


IMG_20200926_121427

Christine found a fabulous little cabin for our getaway in a little village which in the 60’s and 70’s was the center of an area filed with “hippies” from around the world who built a lot of treehouses which have now evolved into little resorts with 2-10 small cabins on the property.  So I left the shipyard very early Friday afternoon at 15:30 and we packed up the pups and some snacks and were on the coastal road by four. 
We checked into our little cabin and then spent a few hours walking through the small village along the river front which filled with lots of arts and crafts shops, cafes and restaurants which led us down to the pebbly beach where our boat dogs Ruby & Barney enjoyed  being back to salt water beaches after almost three years of being dirt dwellers with us. 

As you can see in the photo above, the beaches are as usual jam packed with other people.

IMG_0638The little “resort” we were at was run by a lovely Turkish family who cooked up a fabulous dinner that evening in an open air patio where we were almost the only guests to enjoy the owners excellent selection of jazz music during our long and leisurely dinner. 
Our host family again delighted us with a classic Turkish breakfast the next morning and we spent the rest of the day driving along the coast and up into the mountains to explore everything from Lycian tombs (click photo on left to enlarge) to mountaintop Roman ruins complete with amphitheatre and acropolis. We treated ourselves to dinner at our local marina which is only a few blocks from our apartment and the whole experience felt like much more than just an overnight getaway that really helped recharge our batteries for the final push to finish Möbius and Launch!


Back at Naval Yachts, it was another week of disappointedly limited progress on XPM78-01 Möbius herself as their other boat projects seem to take precedence.  The bright spot though was that our dynamic duo of Uğur and Nihat make a LOT of progress on the Davit Arch as they finished welding the Davit Arch onto the Aft Deck and it is now ready for rigging. 

In the Master Cabin, Serkan continued his single handed work installing the last of our favorite SS latches and he and Sinan completed installing the leather covered panels on the upper cabinet doors and the Bureau of Drawers.  Out on the Aft Deck, with Uğur welding the Davit bases to the deck, Nihat turned his attention to installing the EPDM foam insulation in the overhead roof and the big ER Deck Hatch. 

So grab a comfy chair and a favorite beverage and join me for this week’s Show & Tell Progress Update aboard XPM78-01 Möbius.

DAVIT ARCH:

Might as well start with the star of this week’s Show & Tell; the Davit Arch! 

Retrieving any dinghy in rough weather can often be eXtremely dangerous so we have been working since the early design stages with Dennis over three years ago now, to design a Davit system that is as safe and as fast as possible. 

Christine and I hope that our fellow cruisers who have launched and retrieved their share of dinghy’s and tenders will weigh in with your thoughts on this system by adding your comments and questions in the “Join the Discussion” box at the end of the blog. 

First a couple of quick renders to show how we’ve designed this somewhat unique launch/retrieval system for the jet drive Tender to Möbius which you’ve seen being built in the previous weeks. 


Davit   Tender Up Down positionsWe had a very good hinged Davit system I had designed for the aft end of our previous sailboat that worked extremely well to launch and retrieve our 4m/13’ aluminium bottom RIB in under a minute so we took all the lessons learned there and used them to help guide us in the much more greater challenge of having a similarly safe and fast Davit system for our now 5m / 16/5’ 1100Kg/2400lb aluminium inboard diesel jet drive Tender. 
Right now Möbius is sitting too close to the boat next to it inside the shipyard to be able to do a dry run lifting the Tender On/Off the boat so we will have to wait until we launch to find out in real world terms how well this design is going to work.  However, between the two of us, Christine and I have cruised for many decades now and have launched and retrieved dinghy’s thousands of times spanning the full spectrum of different sizes and types of dinghy’s and tenders using an equally wide range of davits and we think this Davit Arch system will prove to be the safest and easiest to use Davit system we have ever used.  Stay tuned for that real world testing report in the next few months.


Davit   Tender Up on Deck PortAs you can see we have used the same type of “ladder” construction for the Davit Arch as on the Main Arch as this style has proven to be a Goldilocks combination of strength to weight and we also really like the overall visual esthetic of this matching pair of arches and how well it fits in wtih the overall eXpedition look of XPM78-01 Möbius.
Davit 3 piece Joiner plates renderI updated the design just before we ordered the aluminium to make the arch a three piece assembly that bolts together very simply using two doubler plates (light blue in the model) at the transition between the vertical legs and the horizontal beam. 
This allows us to dismantle the arch and take it down completely either in what we refer to as “Hunkered Down” mode in preparation for an impending cyclone (ask us how we know!) or for “Canal Mode” when we want to eXplore inland canal systems found throughout the world that have bridges with height restrictions lower than our air draft with the Main Arch and Skybridge roof and Davit Arch up.
Raising/lowering the Tender will be a very simple two stage operation and I will explain this all in much more detail wtih photos in a future Weekly Update when we start doing the two sets of rigging. 

1.   One set of rigging will move the angle of the Davit Arch itself from the near vertical Cyan coloured position you see in the first render above that puts the Tender fully up on deck and then lets the Davit Arch move sideways  towards the Port/Left side until it reaches the Purple coloured position where the Tender is now clear of the Deck. 

This rigging will be an all Dyneema setup starting with two attachment points at the Forward/Aft end of the overhead beam connecting to a a single line extending over and down through a turning block straight across the Deck on the Starboard/Right side Rub Rail and then lead to the big EST 65 Lewmar electric winch in the middle of the Aft Deck. 

2.   The second rigging will be a double set of vertical hanging lines to raise/lower the Tender in the Davit.  When the Tender is up on Deck these will raise/lower the Tender from its chocks and when over the side it will raise/lower the Tender from the water.  This will also use Dyneema line attached to a bridal clipped to four attachment points inside the hull of the Tender leading up to a block and tackle handing down from the Front and Aft ends of the overhead beam and leading back down to two EST40 Lewmar manual winches mounted inside of each vertical Arch leg.

With all that in mind let’s go see how Uğur & Nihat, aided by their student intern Omer, made this all come together this past week.  I will use the same technique as many seemed to like in covering the build of the Tender; a rapid fire set of photos with just a little bit or text along the way.  Here goes………………….

IMG_20200921_150444If you would like to review the building of the various components of the Davit Arch system you can look through the past 3 weeks of posts which covered their construction.  This week Uğur began by machining the two large cylindrical Hinges; one at the base of each vertical leg of the Arch.


IMG_20200921_150448He had welded the two Base Plates out of 20mm/ 3/4” AL plate a few weeks ago so now he was ready to machine the 100mm / 4” OD aluminium cylinders that fit between the two triangular sides on the Base Plates and the two SS Hinge Pins that slide through to create the Hinge.
IMG_20200922_110015KISS, Keep It Simple & Safe design for the whole hinge with these two SS Hinge Pins that have an end cap bolted on to keep them in place and snug up against the sides of those triangular support arms on the Hinge Plates.
IMG_20200922_150008While the Hinge Pins were being machined, Uğur and Nihat mounted the AL cylinders into the holes in the 25mm / 1” thick plates at the base of each vertical leg.  Some scrap pieces of AL were tacked on to hold the cylinder in perfect alignment and then welded them fully in place with multiple passes on each side.
IMG_20200922_181245All three parts now complete and ready to be bolted together to form the completed Davit Arch.
IMG_20200922_181256Aligning the holes in the two doubler plates.
IMG_20200922_181305And securing them with six 16mm / 5/8” bolts.
IMG_20200922_181437Torquing down all the bolts, Hinge Base Plates ready to be attached with their SS Hinge Pins.
IMG_20200923_094732Like this.
IMG_20200923_122659et Voila!  The Davit Arch is upright for the first time and ready to be moved up onto the Aft Deck of Möbius.

But how do we do that when the forklift can’t lift the Arch up high enough???
IMG_20200923_134305Simple!  Uğur quickly fabricates this Forklift Crane eXtension (patent pending) using some scrap lengths of 8” square steel tubing with a chain hoist and block hung from the top and the base jammed into one of the forks of the forklift.

Oh, and a couple of strong men to help steady the Arch in place.
IMG_20200923_134815Up Up Up goes the Arch ……..
IMG_20200923_135006……… as Uğur inches the forklift into the very tight space between Möbius and Twinity, the big composite catamaran hiding behind the scaffolding and plastic on the Right here.
IMG_20200923_135923The Forklift was till a wee bit too short for the Aft Hinge Base Plate to clear the deck but some pry bars and muscle helped to raise it the last few inches and the Davit Arch was no up and ready to be positioned precisely on the Aft Deck.
IMG_20200923_144927The laser level and a long tape measure allowed us to get each Hinged Base Plate in the same position that we had worked out on the 3D model.
IMG_20200923_151455And each plate was tacked in place so we could do some real world measurement and testing to make sure the somewhat complex geometry all worked out as in the 3D model for getting the Tender to clear the outer edge of the Port/Left Rub Rail and then get it fully on Deck to meet the requirement that no part of the Tender extends out past the vertical line of the outer Rub Rail.
IMG_20200923_151519A worms eye view from the Swim Platform looking up the Aft Vertical leg of the Davit Arch and a good vantage point to see how the Davit Arch hinges on the Base.
IMG_20200923_153338Our digital level was a big help in checking the angle of the vertical legs when they are in the fully upright position where the Tender will be Lowered/Raised on the Aft Deck.

We designed this to be just a bit less than vertical so there was always a bit of weight on the rigging when the Tender was hanging from the Davit Arch so the Arch would start to move as you loosened the line on the winch and belayed the line to move the Tender sideways and over the Port side where it can be lowered into the water.
IMG_20200923_153345Now I needed to see exactly where the Centerline of the keel of the Tender would be when lowered onto the Aft Deck so I scrounged around the yard and found two of these weights.  Not sure what they are or used to be but they worked just perfect to be Plumb Bobs that I could string from the top of both ends of the Davit Arch and mark the spot on the deck with my felt pen when the Plumb Bob string was exactly vertical.
IMG_20200923_162425With the forward and aft Plumb Bob points marked, a laser level and a 6 meter length of aluminium L-Bar provided enabled me to lay out the full centerline on the Aft Deck and then use this as our reference line to measure the position of the Davit Arch and Tender as they moved from fully onboard to fully off the Port side.
IMG_20200924_120714It took me several hours of laying out all the positions of the Tender and its clearances over the side as well as clearing the Port Vent Box you see off to the Left of the front Hinge Base.

We tried out about three different positions and tacked the bases in each one as you can see evidenced here with some of the previous tacks that were ground off so we could reposition and get that Goldilocks just right spot.
IMG_20200924_162119 You can see some of the different locations and colours I marked out on the deck until I though it was just right.
IMG_20200924_162655and gave Uğur the go ahead to weld them fully in place.
IMG_20200924_162201Here is what the Forward Leg of the Davit Arch looks like now fully welded in place.
IMG_20200925_141057And here is the Aft leg of the Arch now fully welded in place just inside the stairwell down to the Swim Platform.
IMG_20200925_141106As mentioned up in the beginning, the Tender is lifted Up/Down in the Davit Arch via two of these EST40 Lewmar winches.  This is the Aft winch.
IMG_20200925_150753And this is the Front Winch.  These EST40 winches have two speeds and are self tailing which should make lifting the Tender up off its deck chocks and out of the water very easy to do.
IMG_20200925_141126Once the Tender has been lifted up high enough for its bottom to clear the side deck, moving the Tender sideways onto the Aft Deck is even easier using this much larger and electric EST65 Lewmar winch.  You can now visualize how this single line from the winch goes up to the two bridle lines that go over to the front and aft ends of the Davit Arch.  And you can now see one of several uses for those two 50mm/ 2” thick aluminium Fairleads extending up out of the Starboard side Rub Rail.
IMG_20200925_095958Once we have the Tender strapped down into its chocks on the Aft Deck all the weight comes off the Davit Arch and I wanted to make sure that it was well secured when we were on passages.  Uğur came up with this simple design of two plates welded to the sides of the roof that sandwich the front vertical leg and ……
IMG_20200925_150753…. is then captured when the Arch is fully raised and rests against the forward side of the Roof overtop of the Aft Deck Galley.  We will make up a pin to slide through the two sandwich plates so that the Arch could not come loose and I may make this with an eccentric cam so I can lock the Arch tube tight against the rubber bumper that will be glued to the Roof edge and make for a nice tight holder that won’t rattle or move.
IMG_20200923_175019It is difficult to photograph the overall Davit Arch so I climbed up on the racks that separate the far bay in the shipyard to get this photo looking down at the Aft Deck of Möbius and Twinity off to its side.

Hope this helps to also give you a better sense of size and scale to the Aft Deck, Swim Platform, etc..

AFT DECK INSULATION:

In between building the Davit Arch, Nihat got busy putting in the 50mm / 2” thick EPDM foam insulation on the underside of the AL roof that extends out overtop of the two Vent Boxes. 


Aft Deck renderThese two Vent Boxes are primarily there to bring fresh air in and stale air out of the Engine Room and Workshop but we put them to double use as our Aft Outdoor Galley by making their tops out of the same Turkish Turquoise marble as in the main Galley and installing a nice SS sink on one side and our electric BBQ Grill on the other.
IMG_20200921_113713Up to now, the underside of this overhanging roof looked like this and so Nihat got busy filling in all those channels with 50mm thick EPDM foam insulation.
IMG_20200924_162457Like this.  Prior to putting in the EPDM foam, he welded in all the short lengths of aluminium L-bar you see here
IMG_20200925_150543…. that will be used to attach the White Alucobond ceiling panels which they started cutting out down on the shop floor beneath.
MVIMG_20200925_100225This is a view of that ceiling looking up from inside the SuperSalon through the main entrance door.
IMG_20200924_162449And while he was in an insulation mood, Nihat removed the large AL deck hatch overtop of the Engine Room and glued in all the 50mm thick EPDM onto its underside.  As with the rest of the walls and ceiling in the ER, this EPDM will next be surfaced with White Alucobond screwed to those AL L-Bars he has welded into the frame of the Hatch.

INTERIOR:

Last but not least for this week let’s go check out what’s been happening with the interior of Möbius.

IMG_20200920_120158The Captain is VERY happy to see these two SS towel warming racks finally show up at our apartment after months of searching to find them, putting through the order, getting them through Turkish Customs and finally getting them delivered.
IMG_20200920_120210They are both the same and one goes in our Master Head/Bathroom and one in the Guest Cabin Head.
IMG_20200920_120454Beautifully made, this is one of the brushed 316 SS valves that connects the towel rack to the SS Hot Water fittings mounted in the walls.  Can’t wait to show you what these look like when they’ve been installed so do stay tuned for that in a future episode here.
IMG_20200925_150921Serkan our Hardware guru, continued with his installation of those lovely SS latches I’ve been extolling ad nauseum the past few months.  He is now down to the last of these as he installs the final four on these lower cabinet doors on the Starboard side of the Master Cabin.  With so many to install and the need for each latch barrel to be in just the right spot, he has build this little jig to make it easier to drill the pilot hole for each latch.
IMG_20200925_100421Sinan had previously covered the panels for all the upper cupboard doors and the Bureau of Drawers with their beautiful Green/Blue leather and Serkan now has them all mounted and installed all their SS latches.
IMG_20200925_100306Looking forward along that same side with the Bed platform on the Bottom Left and the Shower/Bathroom Upper Left, you can see how the Master Cabin is starting to come together.
IMG_20200922_110347Bathroom door now hung and most of the Bathroom cabinets in place waiting for their Corian countertops and then the iridescent blue glass sink can be installed.
IMG_20200922_110330Same style glass Blue sink is in place in the Vanity at the very front end of our Master Cabin.  The upper part of the door will soon have the same Green/Blue leather panel installed
IMG_20200922_110412along with the door handle that will look like this.
IMG_20200922_110447Which is actually the handle installed on the “Swiss” double acting door for the Entrance to the Master Cabin and the tall Wardrobe on the Left.
IMG_20200922_110340I detest drafts, squeaks and rattles so all the interior doors have these silicone based seals inserted into thin slots cut into the corner of each door jamb.  As is so often the case it is the small details like this that make the difference between good and eXceptional and I smile every time I feel the soft squish as I close one of these doors and feel them seal tight as the door latches closed.

Anchor Shackle:

IMG_20200923_174111In the Absolutely Must Have category as well as the “Don’t ask me how long it took to get these here” category, it put an even bigger smile on our faces when these Crosby anchor shackles finally arrived.  Our anchor chain is 13mm / 1/2” but we were able to upsize the critical link between the chain and the anchor to this 16mm / 5/8” shackle.  One of the key bits of kit that truly help us Sleep Well At Night or SWAN as we often call it.
And THAT my family, friends and followers is a wrap for the week that was September 21 to 26, 2020.  Hope you enjoyed this week’s Progress Update and PLEASE let me know your thoughts, concerns and questions in the “Join the Discussion” box below.

Thanks for joining and I hope to see you here again next week.

-Wayne

Latches, Hatches and Bling Oh My!! Weekly Progress Update XPM78-01 Möbius Sept. 14-19, 2020

The “skeleton” version of Team Möbius was leaner than ever this past week here at Naval Yachts as we are down to just two part time workers onboard Möbius this past week.  However, along with Christine and myself and our Dynamic Duo of Nihat and Uğur we all put in a very full week and they made great progress in finishing all the “hotworks” of welding up the Tender. 

So this will be another shortened version of these Weekly Progress Updates but I’m delighted to share all I have with you.

I will leave the largest progress on the Tender for the end this week and so let’s jump in first to what did get done this week on the Interior of Möbius thanks to the couple of days that our Sparky Hilmi and our Hardware guru Serkan were onboard.

LATCHES:

IMG_20200828_171805I’ve received a lot of comments and questions (thanks!) about these bits of boat jewellery that masquerade as our eXtremely solid latches on all our cabinet doors and drawers and we like them more every time we see them and start to use them.
IMG_20200829_102823For those who have not seen these latches before they are solid 316 SS and work simply with a light one finger lift like this.
IMG_20200831_161453When you add up all the drawers and doors in both cabins, the Galley, the Corridor Office and the Salon we have a LOT so Serkan has been a busy boy getting these all done. 
IMG_20200829_102909It might sound as simple as “drill a hole and thread the latch body in place” but it is actually very eXacting and finicky work to get the holes in just the right location so the latch mechanism lines up.  Adding to the challenge all the Rosewood doors and drawer fronts have already been finished and polished so drilling these holes without any splintering or pull outs takes some finesse.  But Serkan is appropriately OCD when it comes to the quality of his work and hey now as almost all the latches installed but for a few in the Master Cabin.
IMG_20200903_102446Such as these two drawers underneath Christine’s Office Desk.
IMG_20200831_111853These ones in the Galley Drawers,
IMG_20200901_094428Galley Garage doors,

I hope to be able to show you all the latches in the Master Cabin in next week’s Progress Update.
IMG_20200918_182602Up at the Main Helm, Serkan and Hilmi worked together to mount the em-trak Class A AIS I mentioned last week.

It is the rectangular screen you see here in the upper Right corner of the Black leather ceiling overtop of the Main Helm.

IMG_20200914_100738Another example of those “how hard can this be?” jobs as there are a lot of different cables that Hilmi had to run from a lot of different locations on the boat with the AIS antennae being up on the Main Arch, the dedicated AIS GPS head up on the front Port side of the Pilot House, data cables going to the N2K system and +/- 24V cables to power the whole thing.
IMG_20200918_182552

Serkan then needed to put the hole for all these cables in the Black leather covered removable ceiling panel overhead of the Main Helm and then attach the holding bracket that the em-trak AIS unit attaches to.

IMG_20200918_182539

Positioned for clear viewing whether seated or standing at the Helm and the whole unit can also pivot and tilt so we can orient it to keep an eye on when eating at the Dinette Table or in the Galley.

HATCHES:

Open HatchSince we first started installing them, I have also received a lot of questions and comments about the Deck Hatches I designed and we built in house here at Naval Yachts.  Boat owners, especially those of us doing long passages, typically have a love/hate kind of relationship with Deck hatches.  Just Love all the light and fresh air they bring in BUT they almost all start leaking relatively early in their life. 


Of course, Mr. Murphy ensures that when they do leak, that water will always land in the most annoying spots such as in your face as you sleep, soaking your bed or seats or dripping onto electronic gear.  Ask me how I know??!!!!
Hatch Section labelledTherefor, one of our priorities when we were designing Möbius was to make sure that we had eXtremely Leak Proof Hatches!  After many months of research and sketching, this is the design I came up with in my favorite 3D modeling program, Fusion 360.
Hatch Section with edge seal infoThese two section views shows some of the key features to ensure these stay fully waterproof with large self draining gutters around the flush mounted 15mm glass lids and edge seals around the inner frames.
TrimLok hatch sealsI spent a LOT of time searching for the Goldilocks edge seals and finally found them at Trim-Lok in the USA which makes the seals for many automotive manufacturers and other industries.  Trim-Lok has a great site that allows you to custom design your own seals with an interactive “Hatch Seal Product Builder” where you chose details such as thickness of the “edge” the seals will attach to which in our case is the 8mm thick upper vertical edge of the aluminium inner hatch frames.  Then you chose which side, A, C or E you want the “bulb” part of the EPDM rubber seal to attach to and the width or “leg length” of the grippy rubber U-section you want.
TrimLok Hatch seal dwg 2 closedI designed these Inner Frame of the Hatches and then the Trim-Lok Hatch Seals such that as you close the Hatch Lid, the upper rubber bulb part of the seal is compressed to the Trim-Lok specifications for the just right and maximum sealing.


Once you have your seal all designed you just specify things like colour, type of rubber and how many linear feet you want and they ship it to you all coiled up in a box.  It is always a treat when I can work directly with the manufacturer and it was a great experience working with Trim-Lok to design and build the Goldilocks Hatch Seals for Möbius.


IMG_20200904_133309This is what those Trim-Lok seals look like in the real world aboard Möbius.  Pretty self explanatory; the deck surface is on the far Left here and then you can see the deep Gutter formed by the Outer AL Frame and one of the two drain holes in the bottom.
IMG_20200904_133305Christine and I spent some time last week doing a test fit installation of the Trim-Lok seals on this one hatch up in the ceiling of the “doghouse” overtop the entryway into the Workshop off of the Swim Platform.  3D modeling and custom Hatch Seal Builder tools are great but they are still all theoretical so we were anxious for this real world fitting. 
Fortunately the seals and the hatches worked even better than we had hoped.  The “squish” was just right both for maximum sealing as well as the just right about of resistance as you lock or “dog” the hatch handles down.


Hatch Hinge Boxes close upJust to up the challenge, I added some other requirements for this design such a having their glass tops be flush with the AL decks so they are no edges laying in wait to bite your toes as you walk around on deck usually in bare feet.  Perhaps even more importantly,  no edges to snag lines and ropes.


However the #1 feature attracting me to Flush Hatches is that when you take on big waves breaking over the bow or sides, flush hatches have no edge for this deluge of water to press against the seals as it all runs straight overtop.


Hatch Hinge Boxes insideAnd If I’m going to have no protrusions of the Hatch Lids, then surely I had to also get rid of the Hinges right?  So the renders above and on the Left show how I made the hinges disappear when the Hatches are closed.
Hatch Latch & Handle sketches[3]Recently I completed what I felt was the Goldilocks design for the latches and handles for these 10 Deck Hatches and had them all CNC milled from billets of solid aluminium I had on hand. 

Hand sketching is my preferred method of thinking through a design and coming up with lots of alternative ways of meeting my design goals.
Hatch Handle square designThese are two of my early sketches for the Hatch Handles and Latching system that I ended up with. 
Hatch Handle closed Fusion 360Once I have the basic design details worked out in my sketches I then move over to Autodesk’s Fusion 360 ** to work out the precise details and end up with a fully developed 3D model that can then talk to the CNC milling machine to make them.
** Full Disclosure, I was privileged to work for Autodesk Inc. for over 25 years so I may be a wee bit biased but I continue to be amazed at what all they have been able to pack into Fusion 360 and yet keep it so amazingly easy and powerful to use.


Hatch Handle detail latch onlyI’ve removed the Handle here to show how the round Upper Boss is bolted to the 10mm thick CNC cut Hatch Lid which the 15mm Glass will soon be glued to.  The Purple part below is the 20mm thick Latch Block or Plate where the “nose” of the Handle slides under to pull the Lid closed.
Hatches with Handles Iso view in Fusion 360I’ve made all the parts somewhat transparent in this quick render to give you a bit of X-Ray vision to see how all the various features such as the Handles, Lid and Hinges all work together.  Click this or any blog image to enlarge it for a closer look.
IMG_20200904_155303Here’s what one of those Hatch Handles looks like over in the real world.  That Latch Block on the Right has two threaded holes on the back side where it is through bolted by two SS Hex-Head bolts going through the Inner Frame.
IMG_20200904_155706First test fitting of a pair of Hatch Handles.

This is how the Handles are oriented in their Closed position.
IMG_20200904_170443And this is where the Handles sit in the Open position.
IMG_20200904_155229The smallest three of the ten Deck Hatches are 450mm / 18” square and their width is too small for the two Handles to fit when you move them to the Open position.  My KISS solution was to make one of the Handles a mirror image of the other like this so their ends can overlap and yet still give you the full size handle to close.  Worked out very well.
IMG_20200904_135421As you can see from this design, getting those round Handle Bosses bolted to the Lids in the exact right position is quite critical to them working properly so after a bit of pondering here is the technique I came up with to mount all 20 Bosses.

First lay out the exact center of the Boss and Handles with some calipers and a center punch to position the point of the drill bit.
IMG_20200904_152235Drill and Tap that hole and thread a length of an M8 – 1.0 threaded rod through it.
IMG_20200904_152300Then thread the AL Boss onto the rod and tighten the rod to hold it in the correct alignment for drilling the four bolt holes.
IMG_20200904_143003Getting those four holes all drilled in just the right spot was the critical part of this challenge and the fun trick I came up with was to use the CNC machined AL Bosses as their own drilling jigs.  Once I had them tightened up with that center through bolt, I then made up a little “pipe” that had the outside diameter to fit snuggly inside the four holes in the Bosses and then used a drill bit that was the same size as the inside diameter of the SS pipe.
IMG_20200904_143035A bit time consuming with 80 holes to drill and tap but t worked like a charm and I just repeated this process for all 20 Bosses.
IMG_20200905_140143One of the 650mm square Hatches is underneath the circular staircase going up to the SkyBridge so it was a bit more challenging to get at but it too was soon all drilled.

IMG_20200904_144743With the holes drilled in just the right locations it was straightforward to tap each hole with M6 threads
IMG_20200904_145651Put a bit of Loctite on each SS bolt and torque them down just right and they were soon all done.
IMG_20200904_155303Next challenge is to get all 20 of these rectangular Latch Blocks bolted in precisely the right spot on the Inner Frames and I’m hoping to get to that next week so stay tuned.

TENDER:

At the opposite end of the progress spectrum, Uğur and Nihat put in a very full and very hot week working on the Tender to Möbius and I’ll do as I have been in previous posts and show you their progress with a rapid fire series of photos and a bi of text along the way.


IMG_20200914_103901

With the “Mickey Mouse” opening in the 20mm thick Transom Plate all cut out we wanted to do another test fitting of the Castoldi 224DD jet drive and then mark the centers of all the holes around both the rectangular frame on the bottom and the Transom.


IMG_20200914_104937I also needed to check that the two hydraulic cylinders that mount through Mickey’s ears had the right amount of clearance so I climbed inside the Tender, cylinder in hand while the boys lowered the Castoldi into place above me.
IMG_20200914_100454Perfect fit on the inside.
IMG_20200914_100350And the outside at this critical 93 degree angled corner between the bottom of the hull and the Transom.
MVIMG_20200914_113936Centers of all the holes laid out before removing the Castoldi, center punched each one and it was quick and easy to drill all the holes in this Frame and the Transom.
IMG_20200914_115735Christine keeps remarking that she can’t get over how bit our “dinghy” is to which I reply, “Look Up!”  Looks pretty small now don’t you think?
IMG_20200914_122053With the Castoldi jet drive all fitted and holes all drilled and all the bottom welding finished,  it was time to flip the hull back right side up again.
IMG_20200914_154141And get to work putting in the rest of the CNC cut 6mm AL plate.

Engine Beds now all welded in and the inner walls of the hull getting tacked in place.


IMG_20200914_181905Time to assemble the Swim Platform which doesn’t take them too long.
IMG_20200915_094808A quick test fit and Uğur welds it all up.
IMG_20200915_122058This is going to be a great platform that will make snorkeling and Scuba diving SO much easier than from a RIB as well as making rear boarding very easy.
IMG_20200915_122107However the primary purpose of the Swim Platform is to protect the Jet Drive bucket and nozzle from docks and rocks at the rear and it will do an eXcellent job of this too.
IMG_20200915_171335Starboard side Console shaping up nicely as well.
IMG_20200916_151117As is the platform of the seats behind.
IMG_20200917_114013Test fitting the tacked up Lid over the Engine Bay.  It will be hinged at that forward seam and lift up with the assistance of two gas spring lift cylinders like the rear hatch of an SUV.
IMG_20200917_114321Nihat opens up the forward 100L fuel tank that will provide an access port for cleaning and servicing.
IMG_20200917_172410Inner frame for the access port tacked in place.

Uğur was now able to get inside to finish welding this fuel tank from the inside to fully seal it off from the two side “tanks” which we will most likely use for additional dry storage rather than fuel.


IMG_20200918_114822Holes drilled and tapped, gasket made up and in place.
IMG_20200918_114806Uğur the Ninja Welder soon had the dashboard all welded up and bolted the SS piano hinge in place.
IMG_20200919_120251We used the same edge seals as for the Hatches you saw above around the circumference of the hinged dashboard to keep it all weathertight.  Once I get to fitting out our Tender I’ll add some latches for this Dashboard, the Engine Lid and other access hatches throughout the Tender but that is much further down the priority list right now.
IMG_20200918_181931Et Voila!  The Center Console is pretty much all welded up.
IMG_20200919_120301Ever the productive one, Uğur spent a bit of time in the machine shop and whipped up these two hinges that he will weld on next week to the Engine Lid.

So stay tuned for next week’s episode of “How the Tender Turns”

Mr. GEE


IMG_20200918_182252I spent quite a few hours with Mr. Gee this past week and while not too visible yet, got lots done in terms of the mounting some of the critical equipment he will be powering such as the two 250A @ 24V Electrodyne “Big Red” alternators one of which you can see here in the upper Left corner.  That one will mount to a beefy bracket I designed this past week that will bolt to the flat horizontal pad you can see above it on Mr. Gee’s front Left corner.
IMG_20200918_133902I also spent a few hours setting the camshaft timing and the valve clearances.  This photo is showing the simple process of setting the clearance between the ends of the valve stems and the rocker arms using a 0.008” for the Exhaust valves and 0.004” for the Intakes. 
IMG_20200918_182245And in case you were wondering what the “Bling” in this week’s title was referring to, I spent a few minutes on the polishing wheel to see how well these little access port covers on the two cylinder heads would polish up.  Still very crude as I need to spend much more time prepping those surfaces, but I think this will add a Goldilocks nice touch of class to Mr. Gee to great you as you enter the Engine Room!
And that folks, is the week that was September 14-19, 2020 here in Antalya Turkey aboard the good ship Möbius.

Thank you SO much for joining me and even more thanks for posting your questions and comments in the “Join the Discussion” box below.

Ciao for now,

-Wayne


Let There Be LIGHT! Progress Update XPM78-01 Möbius Aug 31-Sept 05, 2020

Similar story this week as the past few; excellent results and exciting progress on Möbius wherever Naval craftsmen have worked, just not as many of them working as are needed to finish and launch Möbius as quickly as possible when they are assigned to work on other projects in the shipyard.  But forward progress towards the eventual Launch Date made none the less.

As I gathered all my photos from the past week together there seemed to be a theme of light than shone through many of them in different ways and hence this week’s title.  So let me go shine some light on all of these and jump right into this week’s Show & Tell and show you some of those eXcellent results and eXciting progress from this first week of September 2020.


INTERIOR PROGRESS

IMG_20200819_182436Lots of Light shining through in the interior such as this is one of very many LED light fixtures which are inserted into the removable ceiling panels in all the living spaces.  These are made by the big Italian lighting company BCM and we are using their BCM Charlotte 80 LED lights for most living areas.


IMG_20200819_182434

These are the newest generation LED lights which are significantly more efficient so their wasted heat is very small and the large heat sinks you may be familiar seeing on such LED fixtures are no longer required so these lights are much smaller and cooler, both literally and figuratively.


IMG_20200819_182603

Typical Italian craftsmanship and quality, they are easily set into the holes cut into the ceiling panels by folding the two spring loaded arms out of the way and then orienting the outer polished SS frame however you wish.

All our lights are LED so our overall energy consumption and heat generation is kept to an absolute minimum and all lights are on dimmer switches so we can easily have the Goldilocks Just Right lighting in every location and situation.


IMG_20200826_095519

Lights over larger living spaces such as these overtop of the Lounge on the Left and the Dinette on the Right are a Warm White, about 2700 – 3000K.


IMG_20200826_095538Whereas task lighting situations such as these in the Galley are a cooler  Neutral White of 4000-6000k.  We also have some up here in the SuperSalon that can be switched to a coloured Red/Blue light when we are on night passages and want to maintain our night vision.
IMG_20200831_161453Serkan, our interior hardware installer, continues to make his way throughout the interior installing all the positive locking latches and gas struts the many cabinet drawers and doors.
IMG_20200829_102823I’ve shown these to you before but I’m still madly in love with what are to me jewellery like SS lifting latches for all our drawers and cabinet doors.

Single finger lift like this to unlatch and then they are spring loaded so they automatically self latch when the Blum soft close feature of each drawer slide gently pulls the drawer closed.
IMG_20200831_145256Hakan ordered this range of telescoping gas spring struts so we could try them out and chose the ones that were just right for our Garage Doors and fold down cupboard fronts. 
IMG_20200901_094437In the case of these Galley Garage doors, when you lift the latch the gas springs automatically raise the doors to their fully open position and hold them there while you get at whatever you need inside.
IMG_20200902_095446Whereas for cupboard doors such as these lower two in my Corridor Office where the space behind is too shallow for a pull out drawer, the gas struts gently lower the door down when you unlatch them.
IMG_20200903_102446In the case of “regular” drawers such as these below Christine’s Office desk, no struts are needed because when you unlatch them the drawers slide out effortlessly on their Blum SS roller bearing drawer slides and then close automatically with the soft close feature when you give the drawer a gentle push to close.
IMG_20200831_101503The removable Teak floors inside the Heads and Showers have moved on to their next stage of completion with the Black joining compound now all sanded down to a flush surface and are now ready for their fiberglass bottoms to be applied.

ELECTRICAL PROGRESS:

Hilmi our one and only “Sparkie” or Electrician continues to make steady progress with all things electrical onboard Möbius which covers a LOT of different aspects from lights you see above to cabling, connections, circuit breakers, switches, controls and other electrical devices ……………

IMG_20200902_100721………. such as this UDST 800 Ultrasonic Depth/Temperature/Speed transducer in the Bow.  As you may recall seeing last week this transducer is installed inside an otherwise unused integral tank in the hull so that in the unlikely event that we somehow managed to scrape the whole transducer off the maximum amount of water we could take on would be small and self contained within this WT compartment.
IMG_20200902_100735Hilmi has now installed the N2K cable from the transducer up out of the WT compartment through this cable gland which keeps the tank fully watertight.
IMG_20200831_101954Up in one of the highest spots on Möbius, Hilmi has all these MC-4 connectors installed in SkyBridge roof for each of the eight 320kW solar panels that form the roof as well as the other six solar panels fore and aft of this.  In addition to a fully sealed twist lock connector, we use this model that contains a 15A fuse inside which can be easily replaced with a simple twist.
IMG_20200831_102003All the wiring in the SkyBridge roof is now installed in these two cable trays that run down each side of the center rectangular AL extrusion that forms the ridge of the roof and then travels down the inside of the Main Arch tubes to make their way down to their connections to the 14 Victron 100/20 SmartSolar MPPT controllers in the Basement.
IMG_20200902_122534One last bit of electrical detail for those interested are these Swiss made Belimo 24V vent air damper activators.  These connect to a set of louvers inside the Vent Box and Open/Close them as required.  They are normally closed until they are activated as part of the start up sequence for Mr. Gee, our main engine, and allow fresh air in through the Port side Vent Box and extract it back out through the Starboard side Vent.
IMG_20200902_122540The dampers are also part of the Automated Fire Extinguishing System which would immediately close off all these vents and shut down Mr. Gee so that the aerosol Fire Extinguishing gas stays trapped inside the Engine Room with no air able to enter or leave and the fire can be quickly extinguished.  This heat activated sensor adds an additional level of Safety if the FFE does not work by closing the louvers anytime it senses a temperature higher than 72C/160F.  There is also a manual crank that you can use to close/open the louvers at any time in case of an electrical failure.

Fire is probably the scariest thing aboard a boat so we take it VERY seriously and take no shortcuts to ensure that we are alerted as early as possible  to any rise in temperature, any smoke or gas or heat and can take action immediately as needed.

AFT SOLAR PANEL BANK:

Light of a different kind or at least purpose was also the focus this week as Uğur and Nihat, along with our student intern “Omer” from Istanbul Tech University, took time away from building the Tender to Möbius to build the racks and mount the three 320kW solar panels that mount on the cantilevered roof above the Aft Deck Galley.


Fwd Stbd SkyBridgeWe have 14 solar panels in total which are in Purple in this quick render.  3 on the angled & hinged frame overtop of the Pilot House, 8 which form the roof over the SkyBridge and 3 on the Aft Roof.

Total Solar Wp (peak watts) is about 4.5kWp and each panel is wired to its own Victron 100/20 MPPT controllers in the Basement.
IMG_20200901_170836As always we did our best to KISS or Keep It Safe & Simple, the design of these racks to mount the three Solar Panels.  Four lengths of 30mm / 1” aluminium L-bar with mitred corners.
IMG_20200903_165554It took Nihat minutes to cut, fit and weld these frames and then he and Omer tested them with the actual solar panels to make sure it all fit just right.
IMG_20200904_140747With the solar panels removed the three frames were easy to lift up onto the roof where they were tacked together with the center panel offset Aft to match the angled end of the roof and reduce shading from the Main Arch and Paravane A-Frames in front.
IMG_20200904_170545To make it easy to attach and remove the solar panels, these short lengths of 50mm/2” L-bar were welded to the roof and matched up with same size L-bar brackets around the edges of the Frames which can then be easily through bolted to the brackets on the roof.
IMG_20200904_170503This enables the solar panels to be through bolted to each Frame and L-bar bracket when they are standing up and their underside is easily accessed.  Then the assembled Panel + Frame assembly can be bolted to the roof brackets.


IMG_20200904_170609As you saw earlier, the + and – cables hard wired to each Solar Panel have a standard MC-4 twist lock connectors.  I had purchased the matching MC-4 connectors wtih built in 15A fuses and the crimping tools for these which Hilmi is using here to make quick work of installing these MC-4 connectors on each cable that will carry the output from each Solar Panel down to the Basement where they connect to their dedicated Victron 100/20 SmartSolar MPPT controllers.
IMG_20200904_183114Hilmi worked hand in hand with the Framing team to have them mount this cable tray to safely carry the six cables from the Solar Panels over to the cable penetration they welded into the roof.
IMG_20200904_183123Where the cables are then fed over through the penetration into the interior of the Pilot House where they get routed down into the bank of 14 MPPT controllers in the Basement in an uninterrupted run.
MVIMG_20200904_170529All three Solar Panels now bolted securely into their frames, wires routed on their underside and ready to be carefully laid down onto the awaiting brackets on the roof.
MVIMG_20200904_183035Like this!

All the other 11 Solar Panels have been fully mounted and connected to their MPPT controllers so these three now complete the Solar Panel installation and all 14 MPPT controllers have their indicator lights blinking away.

Well done Team!

TENDER BUILD CONTINUES


Tender JetDrive 009 overall render

Picking up where we left off last week, Uğur and Nihat make more swift progress on building the Tender to Möbius this week.  You seem to be enjoying the rapid fire series of photos as this Tender takes shape so I’ll do the same this week and run through a chronological series of photos so you can watch the Tender come to life.

IMG_20200831_163148Here is where the Tender was on Monday morning.  Hull plates all tacked in place along with some internal framing and the start of the offset center console.
IMG_20200831_101118Seats which double as fuel tanks wrap around the Bow on the Right and upper angled section of the Console in the Left foreground.  Floor framing and hull plates below.
IMG_20200831_101031Console on the Right, seat behind and “Engine Room” as Uğur likes to jokingly call it at the aft end.
IMG_20200831_163246Uğur, checking out the visibility when seated at the Console.  He gave it his thumbs up.
IMG_20200901_121814Raised Bow pulpit shaping up.  We wanted to have a wide flat area on the bow to make it easy to board with the bow pressed against a dock of the transom of Möbius. 


See the Tender render above to see the whole upper perimeter will have a dense tough foam Fender about 250mm/ 10” wide attached which makes the flat at the Bow even wider and good for being a mini tugboat to push other boats or be the auxiliary power for Möbius in an emergency.


IMG_20200901_12330920mm/ 3/4” thick Transom plate tacked in place now. 

Note the etched lines with the “Mickey Mouse” ears which will be CNC cut out later.
3123In addition to this cut out in the transom, the cast aluminium frame in Blue here is supplied by Castoldi and will be welded into the bottom of the hull plates to create the opening where the Castoldi 224DD jet drive will slide in and be bolted in place.
Castoldi 224DDYou can see how the cast AL body of the Castoldi 224DD on the Right will fit into the frame in the bottom of the hull and how the thick vertical plate in the middle will through bolt to the Transom plate.
IMG_20200901_123359Partially wrapped in bubble wrap from the factory, this is what that cast AL frame looks like.

The three cross bars are temporary braces to keep the frame fully aligned while it is welded into the hull and then these will be cut out and the Castoldi jet drive slid in place and through bolted to this frame.
IMG_20200901_12343620mm / .75” thick engine bed plates tacked up.
IMG_20200901_143720Pulling the two upper hull plates into position to create the Bow.
IMG_20200901_144009Upper Hull side plates being led Aft and tacked in place.  Flat bar tacked below to set the curve of this joint.
IMG_20200901_144026Scrap bits of AL tacked across the hull plate joint to keep it flush while tacking both in place.
IMG_20200901_144140Working in Tandem, Nihat presses the two plates into alignment as Uğur moves along with his MIG gun tacking the two plates together.
IMG_20200901_165946All tacked up and ready to be fully welded once some of the internal frames are set in place.
IMG_20200901_170232Bow all tacked up.
IMG_20200901_170241Nihat cleans up the welds before the Bow is welded closed with the top plate.
IMG_20200901_170317Stepping back to see that the Tender is shaping up nicely.
IMG_20200902_094602Tack – Tack –Tack.

Bow is ready for welding.
IMG_20200902_095059Tack – Tack –Tack.

Sides and bulwark tops are all in place.
IMG_20200902_095109Integral floor framing added in next.
IMG_20200902_095304Starting to look like a boat!
IMG_20200902_144724Uğur spends the better part of a whole day laying down the final welds of all those tacked up plates.
IMG_20200902_122124Like this.
IMG_20200902_175027And this.
IMG_20200902_175248Working on his Ninja Warrior Welder look, Uğur cleans up one of the Engine Beds he has welded up and is ready to be welded into the Hull.
IMG_20200903_101420Like this.
IMG_20200903_101448Inside of Hull plates finish welded as is the lower strake and the frames for the floors and the sides of the Engine Bay.
IMG_20200903_151802Floor plates in the Bow seating area lay down quickly along with those leading along the walkway on the Port/Left side of the Tender.
IMG_20200904_091435Inner side plates now ready to be installed and the Console seat box is tacked up.
IMG_20200904_122311Captain Christine is called over for a test fit when she is piloting the Tender while seated at the Console.
IMG_20200904_122317And standing. 

The Captain is happy with both so the work can proceed!
IMG_20200904_183423Console and seat is emerging.

OK, quitting time on Friday so we will pick up from here in next week’s Progress Update.

Hope you enjoyed this rapid fire Tender Build sequence.

STARTING Mr. GEE – TWICE!

IMG_20200831_152406No not quite ready for his first real start up, but I did get time this week to finish rebuilding his 24V electric starter motor.

This is a new set of clutch plates which lock the starter gear to the motor shaft as it slides forward to engage with the big ring gear on the flywheel and spin Mr. Gee to start.
IMG_20200831_165653This is the working end of the starter; the bronze starter gear that engages with the ring gear on the flywheel.
IMG_20200831_200422A quick visit with the sandblaster and two coats of epoxy primer have the starter ready for its final paint job.
IMG_20200901_164031In shiny Black.
IMG_20200901_164047However the start of the starter show IMHO are these bits and bobs which have also been blasted, primed and finish coated with Black epoxy and will soon be assembled into the Hand Cranking starter for Mr. Gee.

Hand Crank lever is in the middle here.
IMG_20200901_164051This chain drive gear uses the lever at the top to engage with a slotted drive gear on the crankshaft such that when you turn the hand crank handle the crankshaft spins.  With the compression release holding all six intake valves open you can get the giant flywheel up to speed, flip the compression release levers off and Womp – WOmp – WOMP, Mr. Gee comes to life!
And I can’t wait to show all ye with so little faith, just how this works in the video I will shoot for the first start-up with both the electric and the hand crank start.

So don’t touch that dial!  Stay tuned here for the next episode of “As Mr. Gee Turns”

Thanks for joining us and see you again next week.

-Wayne


TENDER is not just a BOAT! XPM78-01 Möbius Progress Update Aug 24-29, 2020

TENDER is not just a BOAT! XPM78-01 Möbius Progress Update Aug 24-29, 2020

A full five day work week here for everyone but me it seems as I had mine cut down by almost 2 days while I looked after a hernia that I developed on my Left side last week.  Nothing too serious, I had one on my Right side about 25 years ago and apparently my body wanted to keep all my internals symmetrical so time to fix the Left side this week.

WARNING:  This week’s intro may be TMI as my children used to often say; “Too Much Information” Dad!, so you are welcome to skip down to the next section below if you prefer.

The medical system here in Turkey is absolutely awemazing, easily amongst the best anywhere in the world and so after a few visits for ultrasound and other testing they did the laparoscopic or “keyhole” type surgery on Monday morning and I was released Tuesday noon and was able to stop in to see how things were going on XPM78-01 Möbius before heading home to rest for the rest of the day.


hernia-meshThey ended up needing to put in a 10cm x 25cm (4” x 10”) strip of hernia mesh material which was much larger than they had originally thought because they decided to cover both my Left and Right sides for a more “future proof” reinforcement.


Laprascopic surgery photoThis required three different entry points for the laparoscopes so I ended up with three neat little “bullet wound” looking spots across my lower abdomen which should be fun for future wild tales from Grampa Wayne in the future. Winking smile


Hence the double meaning of “tender” for this week’s Progress Update as it applies to my condition this week and MUCH more importantly the beginning of the build of the Tender to mv Möbius!

Best of all however is that I’m feeling much less Tender every day and the Tender to Möbius is feeling more and more real by the day.

So let’s jump right into this week’s Show & Tell of the overall progress on XPM78-01 Möbius for this week of August 24 to 29, 2020.

TENDER to “my Möbius” (my = motor yacht)

First for some perspective, here are the basic details for the Tender:

  • Length: 5 meters,
  • Beam: 1.8 meters.
  • Material: Aluminium 5083 series,H Series, H321.
  • Powered by internal 110HP/81kW Yanmar 4JH4 HTE diesel engine with direct manual fuel injection
  • Castoldi Jet Drive 224 DD (Direct Drive)
  • Central steering station with sloped dash area large enough for small navigation equipment, display screen, switches, gauges, etc.
  • Twin side by side seats at steering station.
  • Additional seats for minimum of 2 other adults, ideally 4
  • Built in lockers sufficient in number and size to hold typical items including life vests, fire extinguisher, spare plastic fuel jugs
  • Diesel fuel tank integral with hull, 80-100 L capacity
  • Equipped with full cover such that the Tender can be used as the boat’s life raft.
  • Designed to withstand ocean going conditions with waves up to 4m and wind up to 8 beaufort.
  • Engine and propeller system will be owner supplied, small likely 3 cylinder diesel with fixed prop.
  • Tender will have large continuous “bumper” wrapping around both sides and bow sufficiently strong to allow using these Tender to push Möbius and other boats and resist abrasion from rough docks, rocks, etc.
  • Foam collar will be adhered to a custom built recess in the hull for this foam bumper and have a wide flat section across the Bow for pushing.
  • Build in support bars on both side of the flat Bow for safety when boarding from the Bow
  • Swim Step overtop of extruding Jet Drive to fully protect the drive gear when backed into docks, rocks, etc.

Tender JetDrive 009 overall renderHere is what those specs and use case look like when transformed into the final 3D model after many months of working with Yigit and Burak.

Tender JetDrive 009 STBD profileWe also worked with the engineers at Yamaha and Castoldi who helped get the hull shape, dimensions and weight distribution just right.
Castoldi 224DDThe Castoldi Jet Drive 224 DD (Direct Drive) …….
Castoldi jet drive position on hull TD224DA…… is coupled to the Yanmar 110HP/81kW
Yanmar 4JH4 HTE
diesel engine using a Cardan shaft and a Centaflex flexible coupling.

We think this combination will make for an eXtremely safe, fast, fun and dry ride!

IMG_20200819_145710

You may recall seeing in last week’s Progress Update that all the CNC cut plate for building the Tender to my Möbius had arrived and first thing Monday morning Uğur started sending me pictures of he and Nihat tearing into that stack of aluminium and starting to assemble all those CNC cut jigsaw puzzle pieces.


Similar to the building of the Möbius herself, this process of assembling precisely cut, numbered and interlocking pieces to build an aluminium hull boat is very similar to assembling a jigsaw puzzle or plastic model airplane kit.  As you can see if you look closely (click to enlarge any photo) the CNC cutter is programmed to leave tiny little “bridges” or tabs every so often along the through cuts so that the individual pieces stay part of the whole sheet of aluminium so they can be shipped/trucked very efficiently.

I received a lot of comments from last week’s posting of how much you enjoyed seeing the Davit go together so sequentially so I will do the same below with the Tender by quickly going through photos as the build progresses quickly with a bit of explanatory text along they way.  Ready – Set – GO!


IMG_20200825_130652Nihat likes to start by wire wheeling all the surfaces to remove the aluminium oxide layer and provide a super clean surface to weld to.
IMG_20200825_135823Next he uses a cutting disk in an angle grinder to sever all the little tabs and remove each individually numbered piece from the sheet.
IMG_20200826_141258He sorts all the pieces into stacks of similar pieces such as this pallet with all the Deck/Flooring plates.
Tender starting to fabricateThursday morning, Aug 27th, the real fun begins as they start the kit building process by laying the three bottom hull plates on the floor and tacking the vertical frames in place which starts to pull the hull plates into the exactly correct angles.
Tender starting to fabricate 2To shape the more complex curved bow, we used an Origami boat building technique which our Rhino 3D modeling software makes very easy.  This process begins by creating a 3D model in Rhino (thanks Yigit and Burak!), and you refine the shape of the model using hydrodynamic testing to come up with the Goldilocks or Just Right shapes and angles for the use case the hull will operate within.  Then Rhino3D has a “Flatten” function that creates the paths for curved CNC cuts.

In this photo you can see the first Starboard/Right side hull plate laying flat awaiting the Port/Left plate to join the party.
IMG_20200827_095515Captain Christine joins Omer & Uğur to get a sense of the shape and scale of our new Tender.
IMG_20200827_132718Aluminium bars are tacked in place to provide temporary attachment points for the chain tackle to pull the curved cuts into contact with each other.
IMG_20200827_141548This proceeds in stages, welding the plates where they touch as you work your way forward.
IMG_20200827_141620Uğur ‘s keen eye is constantly checking as he pulls the two halves together to ensure that everything stays perfectly aligned as he welds the seam to join the two plates into the finished bow.

To assist with keeping all these compound curves all aligned with each other they have also now tacked the two strake plates to the top outer edges of each hull plate.  This strake helps the water flow both lengthwise and sideways to deflect the bow wave off to the side rather than up the hull and onto those of us aboard.
IMG_20200827_174703Similar process is used to now add the next row of hull side plates and pull them into alignment with the lower plates and strakes and tack them in place as the build continues.
IMG_20200827_174715View from the top makes it easy to see how this all comes together.
IMG_20200827_174737With the Bow end tacked in place Nihat and Uğur clamp the rest of these side hull plates into position and …………
MVIMG_20200827_174757………………… tack them along the whole length of the hull like this.
IMG_20200827_175919Looking at the stern from about the waterline level you can see the profile shape of the hull which is what a jet drive boat wants.  Also makes for eXtremely small Draft so we can travel through very shallow waters with no damage to the coral and nature below or to the hull.
IMG_20200828_101036Integral fuel tank has three sections, one on each side which flow into the deeper compartment on center in front.  The very front bow compartment will be for storage of things like anchor & chain.
IMG_20200828_114019Nihat starts adding in the frames inside each tank and tacking those in place.
IMG_20200828_142724First frame of the center console being fitted.  This will have monitors on the upper sloped surface with controls and steering wheel below and double seat aft.  There will also be an acrylic windshield extending above the top of the AL console for added wind and water protection for the pilot.
IMG_20200828_170318Port side console frame helps to fill in the overall shape and size of the console which is asymmetrically positioned to extend all the way over to the Starboard/Right side hull at the bottom of this photo and leave a walkway on the opposite Port/left side.
IMG_20200828_170342Uğur and Nihat are a great team so the Tender progresses quickly as Nihat tacks the pieces in place and Uğur follows behind doing all the finish welding.
IMG_20200828_170440Still lots of jigsaw puzzle pieces to be added!

Omur our student intern from Istanbul Technical Institute helps out by holding this upper coaming plate vertical for Nihat to smooth the curved edges from where they were attached to the CNC cut plat originally.
MVIMG_20200829_104729Console all tacked up as is the framing for the Floor/Deck plates fore and aft of the console and under the seat base.
IMG_20200829_140828Just for a test fit right now this inner side plate will wait for the internal welding to be completed before being slid into place and welded to the hull.
IMG_20200829_141930Burak kindly plotted some larger scale 2D drawings and shots of the model which Uğur has mounted on this board beside the Tender with Möbius looing on from behind.
IMG_20200829_16305525mm / 1” thick AL Engine Bed plates being test fit on either side of the “Engine Room” area aft.
IMG_20200829_163531Up near the Bow, Nihat has the one piece top deck plate ready for Uğur to weld in place.  As with the main hull of Möbius slot welding is used to weld AL plate to the frames that are inaccessible underneath.
IMG_20200829_164133As we have been doing most weeks, we are working on Saturdays to try to make more progress so this is where the Tender build was at when we finished the day yesterday.
IMG_20200829_164425Did I mention that day time temps are running 34-38C / 93-100F?  Add all the heat from the MIG welder and you have three VERY wet Tender Builders!  Uğur takes a well deserved pause to survey the days work and let the air blow over him from one of two big squirrel cage fans we have setup to blow air across the Tender.

I hope you enjoyed this whirlwind tour of the past three days and this photo is how the Tender build looks at quitting time yesterday.  Tune in again next week and I’ll walk you through the rest of the build of the Tender to my Möbius.

DAVIT ARCH BUILD:

Tender Davit double pipe arch YigitLest you think that the Tender was all that Nihat and Uğur worked on this past week, they also finished building the hinged Davit Arch that we will use to move the Tender On/Off Möbius’ Aft Deck.

Davit Arch laying on shop floorThis is the first test fitting of the three individual segments that make up the Davit Arch.  Two vertical legs on each side which are bolted to the horizontal cross beam above.
IMG_20200825_130602One of the vertical legs on the Upper Left here and the upside down cross beam on the Right.
IMG_20200826_094521For added strength these additional 25mm/1” plates will span the connection between the horizontal beam and the short angled pipes that connect this to the vertical Arch legs. 
IMG_20200826_141459Uğur quickly has them fully welded with multiple passes of his MIG gun.

The plate spanning the two braces will also provide two addition attachment points for the 6:1 blocks and Dyneema the Tender will be suspended from.
IMG_20200825_130720Now time to build the two Hinged Base assemblies where the bottom legs of the Davit Arch connect to the Aft Deck.
IMG_20200826_094309Two of these 25mm/1” thick base plates will attach to the Aft Deck and support the large Hinges.  These two triangular vertical plated form the outer sides of the hinge with the 50mm/2” SS hinge pin fastened in between.
IMG_20200826_152052Due to the camber of the Aft Deck and the different offset from the boat’s centerline, the two hinges are at different heights above the deck.
IMG_20200826_142146These two very thick tubes are the third part of hinge and will be machined to slide between the two vertical triangular pieces above. 
MVIMG_20200822_103047These tubes will be inserted into these large holes in the bottom of each Arch leg where they will captured between the two plates on the Base and rotate on the SS hinge pins that slide through all three parts of the hinge.

Stay tuned for mounting this to the Aft Deck and testing it out in the next week or two.

Mr. Gee Gets All Glossy

IMG_20200829_133019With my shortened week I didn’t get as much time to work on Mr. Gee but I was able to do some more painting and clear coating on Saturday including a good clear polyurethane coating of this aluminium beauty.  This is the rarely seen back side of the massive fuel inject pumps and governor assembly that bolts to the Port/Left side of Mr. Gee.
IMG_20200829_132935Sorry for the poor lighting but this is the side you see and where all the action happens with the fuel injection system.  The six vertical levers for example are what you pull to prime each cylinder and the high pressure injection pumps are located right behind them.


Burgundy part in the foreground is bolted to the flange above it and pumps engine oil through that massive solid Bronze oil cooler/heat exchanger on the other side of Mr. Gee that you’ve seen me rebuilding in previous postings.

IMG_20200829_151824These instructions are cast into the large aluminium Header Tank at the front of Mr. Gee which is like the plastic bottle on your car’s engine where you check and add anti-freeze/water.

I’ve painted these with matching Burgundy and next week I will polish off the tops of the letters to make them a bit easier to read and add a bit more class to Mr. Gee.
IMG_20200829_151832Same thing will happen to the instructions cast into this timing chain adjuster lever.


IMG_20200829_151827And these cover plates which bolt to the sides of the cylinder heads.

Mr. Gee’s Best Buddy; Nogva CPP

IMG_20200827_131049You might think that Captain Christine is “just” the Captain, she was also called up for our all hands on deck work schedule and spent two very hot days cleaning, sanding and masking the Nogva CPP Servo Gearbox that will soon be bolted to the back of Mr. Gee.

Mr. CPP may be small but he is mighty and provides the 2.95:1 gear reduction to Mr. Gee’s already slow spinning crankshaft. 
IMG_20200827_131054

With a CPP, Controllable Pitch Propeller, we don’t have a transmission per se as we go from forward to reverse by simply changing the pitch angle of the four prop blades.

It is called a Servo because it also houses the hydraulic controls that move the Pitch adjusting rod that runs down the center of the prop shaft where it connects to each prop bladed inside the hub of the prop and rotates the four prop blades in unison to whatever angle of pitch we want.
IMG_20200829_104457A VERY cool bit of kit BUT we can’t have his Nogva Red clashing with Mr. Gee’s Gardner Burgundy now can we??  So a new paint job was required and hence the big cleanup and sanding this week. 
IMG_20200829_104713Uğur kindly helped move the Nogva to the far corner of the shipyard near where they are building the Tender so I could paint it there with the big shop doors open.
IMG_20200829_143525Nogva smartly provided a purpose built lifting eye that is centered on the weight of the CPP so we used that to suspend it from the forklift which made it real easy to paint with no supports in the way.
Creepy spray painter of Nogva CPPChristine had done a great job of cleaning and sanding as well as masking off all the rubber hoses, pressure and oil level gauges and al the instruction and labeling plates riveted to the case which made my job of painting him very quick and easy.

At least until THIS creepy single hander guy showed up!
IMG_20200829_143617

Between us though, we soon had Mr. CPP ** resplendent in his matching Gardner Burgundy coat and ready to be lifted aboard Möbius and bolted up to the anxiously awaiting Mr. Gee next week.


** If anyone has a better suggestion for a name for Mr. Gee’s best buddy and our CPP, please add it below in a comment.


FRIDGE & FREEZER INSTALLATION

Fridge - Freezers dry fitted to cabinetryIf you were with us last week you saw the initial fitting of the two 130L Door style Fridges in their Ro$ewood cabinets on the Left and the two 70L Drawer freezers on the Right.
R290   R132A bottles of refrigerantMonday morning the refrigeration team returned to charge all the compressors with their respective refrigerant; Freezers with R290 and the two Fridges with R134A.  The reason for the different gasses is that the Drawer Freezers are a brand new model from Vitrifrigo and they have changed to using R290 which is a friendlier and more efficient refrigerant than the much older R134A standard in most compressors.  However it is not possible to mix the two or simply change refrigerant so we have to stay with using two different refrigerants.  Not that big a deal just means I need to carry a supply of each onboard to use with my vacuum pump whenever a need to fix and recharge the compressors might happen in the future.
IMG_20200825_131332Down in the Basement, directly below the Fridge/Freezer cabinets the four 24V Danfoss/Secop compressors are now fully mounted and recharged.  We ran them for a day and pulled them down to their lowest temperature settings and they all passed with flying colours.  Christine and I can hardly wait to be filling these with provisions when we get ready for our Maiden passage.

SPARKS CONTINUE to FLY ABOARD Möbius

Hilmi our head “Sparkie” aka Electrician was about the only one left of Team Möbius to be working onboard this week but he was his usual busy self and persevered by powering through his still quite lengthy list of electrical jobs needing to be done before we can launch.


IMG_20200826_095519Interior Lighting is one of those lists and that is nearing completion as evidenced by all this bright “stars” above the SuperSalon.  Each one is a fully dimmable LED so in addition to having eXtremely low amp draw they also allow us to fully control the amount of light in each space.
IMG_20200826_095538Each LED looks the same on the outside for esthetics but they are all different on the inside for their different purposes.  Some such as these task lights in the Galley are bright White and higher Lumens so the Chef always has just the right lighting when working in the Galley.  Other locations of warmer light and lower Lumens to best suit the activities there.
SkyBridge LED   wire trays 2More exciting lighting up in the SkyBridge this week as Hilmi mounted and wired the LED light bars on the “ceiling” up there.  Christine and I are still debating how best to finish off these surfaces of the undersides of the eight solar panels that form the roof/ceiling of the SkyBridge.


Solar Panel MC4 connectors in SkyBridge 2Our top priority is to keep a good cool air flow over the undersides of all the solar panels to remove the heat they generate as as heat reduces the efficiency and output of a solar panel to an eXtreme degree.  However we also want this ceiling area to be attractive and in keeping with the style and esthetics of the rest of Möbius so we are pondering different ways to do this.  For now however and to keep things moving forward as fast as possible we will leave this ceiling as is and go with the “industrial’ and fully functional look that is very much in keeping with the exterior of Möbius.
Solar Panel MC4 connectors in SkyBridgeHilmi has installed these 50mm/2” wire trays down both sides of the center “ridge” extrusion and is also using these to hold the MC4 solar connectors. 
MC4 fused connector 2We took the KISS Keep It Safe & Simple and I believe more efficient approach to fusing each solar panel by using these MC4 solar twist lock connectors which also have 15A fuses inside them.  No  extra wiring, no fuse box, easy to access, what’s not to like?
IMG_20200827_100631Speaking of Industrial and Fully Functional, Hilmi finished off the installation of these goodies on the inside frame of the big AL hatch into the Forepeak.

The box on the far Left has the plug in for the hand held remote control for the Maxwell Windlass which is hiding under the cardboard box on the Left and this handheld remote will normally be in the holder on the Right.
IMG_20200827_100638

The large Blue receptacle is where the Forward Shore Power Cord plugs in and the box on the far Right has the requisite RCCB or Residual Current Circuit Breaker.
Marinco-Non-Metallic-Shore-Power-Inlet-16A Twist LockThe traditional marine “Twist & Lock” shore power plugs like this one used in North America are an abysmal design IMHO.
Twist Lock Shore power plugsQuite frankly they “spark” great fear in me given how poor their electrical connections between the plug blades and the socket receptacles are.  Poor connections create resistance which creates heat and leads to these plugs literally burning out on almost every boat I know.  I strongly suspect these Twist & Lock shore power plugs cause more boat fires than we will ever know.
16A   32A CEE 3 prong maleIn any case they are forbidden on our boat and we instead use these CEE style plugs which have three round solid brass rods. 
Marinco-Adaptor-16Amp Twist Lock to CEE 3 prongFor marinas which only have the Twist Lock style we carry adapters like these to adapt our CEE Blue plugs to the Twist Lock style AND these say ON THE DOCK and not on our boat! 
IMG_20200827_100721Our 220V @ 32A Shore Power cords plug into the boat at either this plug in inside the Forepeak …………..
IMG_20200827_180721…….. Or this one in the Aft end of the Workshop by the WT door from the Swim Platform.

These RCCP Residual Current Circuit Breakers or ELCI Equipment Leakage Circuit Interrupter are now required on all CE/ABYC compliant boats. 
IMG_20200827_100711These are very important safety devices which provide whole boat protection similar to what the GFCI circuit breakers you have, or should have, on the 120/220V plugs in bathrooms and kitchens.
Schneider RCCBWe are using Schneider for all our AC electrical equipment and this is the RCCB we are using which must be located immediately after the Shore Power entry into the boat, hence one in the Forepeak and one in the Workshop.
IMG_20200828_114214One last round of exciting work from our Sparkie Hilmi is the installation of the ultrasonic Depth/Speed/Temp “triducer”.  This is our last, I hope, open hole (purposeful) on Möbius so we are now fully water tight.  Yeah!!!
Airmar UDST 800 transduce product shotThe Airmar UDST 800 is a relatively new technology for measuring Depth, speed through the water and sea temperature.

See video at the link above for a quick easy demo.
Airmar UDST 800 transducerThe eXtremely welcome innovation is that the speed sensor has no moving parts such as the paddlewheels we’ve had to use on all previous boats which last for just hours sometimes before they foul with marine growth and stop working.

By using an Ultrasonic sensor the UDST 800 has just a smooth glass surface in the water which will rarely foul and is easily cleaned ever few months with a quick wipe.
IMG_20200828_112932I chose the location for this forward depth transducer, we have a much more powerful and bottom discriminating sensor Aft, so that it would be inside this otherwise unused integral tank.  If you peer down into the open access hatch (click to enlarge) you an see the AL pipe welded into the bottom hull plated and now the Black plastic outer housing is in place where the UDST 800 will be inserted from up here inside the Forepeak.

Why here?  Well, if we should ever have a serious grounding of the bow or a collision that managed to clean off the flush transducer, however unlikely, it means that the most water we can take on is what would fill this relatively small WT compartment.
IMG_20200828_112951Close up of the plastic housing with its very clever self closing flapper valve which allows you to pull the transducer up and out while still in the water and it will close off the gusher of water wanting to pour in while you push the blanking plug in place while you clean or maintain the UDST 800 at your leisure inside the Forepeak.

GALLEY CABINETRY

IMG_20200828_113624We were very disappointed and saddened to find out while I was in the hospital that Omur, who has been our Lead Cabinetmaker for the entire interior build on Möbius the past two years, is no longer working at Naval.  However his craftsmanship lives on and before he left he was able to finish off the matching Rosewood drawer and door fronts in the Galley such as this bank of drawers on the peninsula by the Entryway door.
IMG_20200828_113630Even surrounded by all the protective covering you can get a sense of the quality of Ömür’s work and how he prided himself in always being able to find the Goldilocks Just Right combination of matching grain patterns.
IMG_20200828_171805I have learned in my short life so far that it is the little things in life that often make the big differences and these beautiful solid SS latches is one of my favorite examples onboard Möbius.
IMG_20200828_171818Richard, one of our faithful followers, was instrumental in helping me track down the producer of these lovely latches that I had seen several years previous but could not find again.

Trying out a test mount in a scrap of plywood, you can see the nice big solid SS latch hook on the inside.
IMG_20200829_102839On the upper inside framing around each drawer the matching SS latch plate could not be simpler or easier to install like this.
IMG_20200829_102822Here is how they look when mounted in our drawers.

To operate you just hook your finger under the lower edge,
IMG_20200829_102828Gently lift up against the built in spring pressure to release the latch and the drawer slides out effortlessly on the SS ball bearing Blum drawer slides hidden away below the drawer bottom.
IMG_20200829_102816When you have gotten what you needed out of the drawer a gentle push slides the drawer back into its closed position with the automatic soft close feature of these Blum drawer slides and the drawer is again solidly latched in place.  No forgetting to lock them before you head out to sea or some passing boat’s bow wave sets you rockin’ and the drawers all slide out.

More features we can’t wait to start living with aboard the Good Ship Möbius.
And with that, I shall bid you adieu for this week and go rest my still somewhat tender little body for the rest of this Sunday evening.  I go back to the hospital tomorrow morning for a checkup and to remove the bandages and then I should be all good to go and be fully recharged and ready for the final push to finish Möbius and get her launched ASAP.

Thanks for coming along for the ride this week and hope to see you here again next.  As always PLEASE put in your comments, questions and suggestions in the “Join the Discussion” box below and add any feedback that will help me improve these weekly Progress Updates and make them more valuable and fun for you to receive.

Thanks!

-Wayne