Boat Work

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Cat2Fold and I have been back in Idaho for a little over a month now. With my job happening in fits and spurts, I’m glad I decided to bring her home so I can attend to some necessary maintenance. First on the list was to get my disabled outboard motor running again. Pulling both motors off the boat and bringing them into my shop so I could trade parts from the good motor to the bad motor, seemed like the perfect way to diagnose the problem. After pulling the flywheels off, I pretty much could see the problem right away… the coils that create a charge were completely corroded. Switching the good coils over confirmed my theory.

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The crippled motor now had spark! After reassembling the motor, hooking up some fuel, and setting up a big barrel of water to run the motors in (outboards need water to run in), it started right up! But…it ran like shit! And there was no coolant squirting out of the telltale. So, I took the lower unit off that motor to find my impeller (the water pump fan thingy) in about 8 pieces! Luckily, I had an “old” one laying around that looked new! I install the impeller, reinstalled the lower unit, and after a bit of help getting it primed, there was now water being pumped through the motor correctly, but it still ran like crap!!! I was starting to worry that there was more wrong with this poor power plant than was worth fixing! I pulled the carb, cleaned everything as thoroughly as possible, and after reinstalling…Voila!!! A perfectly running Yamaha 9.9 outboard! I also removed the tiller control handles (which were just unnecessary bulk and weight), adjusted the shift linkage, because it was jumping out of reverse all winter, changed the lower unit seals, and the gear and engine oils. I also rebuilt the retractable motor mounts that had become awfully loose over time.

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These pics show how I removed the lower unit seals with screws and a hammer without having to completely disassemble the drive gears.

Next up was to lower the masts to the ground and de-rig them in preparation for a paint job.

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More importantly than painting the masts, I needed to strengthen up my rudder casings. Cat2Fold is equipped with transom hung, kick-up rudders. The case is attached to the transom of the boat, and then the rudder sits inside this case attached only at its pivot. The cases on Cat2Fold were both getting a bit loose and cracked in spots, and they also sat too low in the water where the actual case was below the water line. My thinking tells me this is not good. Probably in part because we are a bit on the heavy side while cruising for 6 months. Anyway, after looking closely at things, I have decided to flip the case, re-drill and seriously beef up the pivot hole/pin, and also incredibly strengthen up the case itself with a horizontal carbon fiber rib added for stiffness and to act as a strong mechanical steering stop. Flipping it will give the clearance needed to get the case above the water line, and overall the stronger, rebuilt cases should feel better and help ME feel better while 100’s of miles offshore.

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Before starting to work with carbon fiber directly on C2F for my very first time, I decided it would be prudent to practice on something else first. I’ve heard carbon can be tough to properly wet out because it doesn’t acquire a “wet” look like fiberglass does. Anyway with these thoughts leading the way, I decided to fix up a small travel guitar that I had broken repeatedly in the past. I took off the neck of the guitar and covered the entire body with carbon fiber. It was a lot of fun, and now the Tacoma Papoose, carbon edition has been (re)born.

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Cat2Fold is also getting a lot of touch ups. Hardware removed. Hardware added. Holes plugged, sanded, and painted. Broken lights replaced. Older, rusty bolts replaced. Most of the stuff I’ve been working on this past month has been the tedious-but-not-so-expensive stuff. I still need new sails. I’m hoping I can save up enough money to buy a sewing machine, cloth and the materials to build soft wingsails for her. I’ve dreamt about it for too long now. Some sort of wingsail is most definitely in our future. Oh yeah, I also need to save enough money to be able to go use her again…

I here tell if you put your ear to the spar of a land locked boat, not only the ocean can be heard, but the mesmerizing thump of mexican ooom-pa-pa beach music… So when you see me with a PBR con limon and my head stuffed way up inside my mast hole, foot tapping to the beat…you’ll no why.

It seems weird. But, I really LOVE working on C2F. I get nearly as much pleasure out of this kind of stuff as the actual sailing and adventuring in warm, tropical locations wearing nothing but a smile, ocean waves crashing nearby, surfing, freedom, wildness…well, OK…maybe not quite as much… 😉

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3 thoughts on “Boat Work

  1. Looking good!

    When your finished with c2f there is a boat over on Wolverine Way that needs some farkling.

    cheers!

    tk

  2. Brian, we love hearing your story, and being part of it! Jack trying to figure out how to turn a “discarded” Thunderbird into a trimaran. Wants to go faster!!!!! (Can we Skype sometime?) M and J

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