126

(14 replies, posted in General Questions/Comments)

A sheet of ordinary writing paper, saturated with varnish then wiped as dry as possible both sides, and ideally left to dry till its tack free before cutting your gaskets makes a very good thin gasket.  Any spare can be kept for later use. For an emergency gasket a little more durable than brown paper, try the plasticized inner paper bag from a cereal packet.  I have also used the cuff of a thin rubber glove (not a paper thin latex one) on an impeller pump.  If experimenting with gaskets, it may be worth unbolting the pump base from the engine so you can check how freely it turns by hand using a pair of pliers to grip the shaft dog, when assembled and lubricated with washing up liquid.  I have seen an electric pump destroyed by too thin a gasket jamming the impeller till the motor burned up.

If there is excessive wear on the inside of the pump cover plate, and the outside is in good condition, clean it up and flip it over.  According to an authorised Yanmar dealer I know, excessive clearance in the pump will result in early shaft seal failure.

127

(14 replies, posted in General Questions/Comments)

You don't need a long snake, just a new length of stiff fence wire. 
DON'T use a snake or stiff wire if you have internal halyards as it is critical you don't get the new wire twisted round any halyards.  With the mast down, and the halyards replaced by messenger lines, it should be possible to use an existing cable if possible or one of the halyard messenger lines to pull through a new messenger line then fish it through the correct holes with a hooked wire.

When you have a messenger going to the correct place use it to pull through the new cable AND A PERMENANT MOUSING LINE for the next time!

To stop it banging inside the mast use clusters of  three small cable ties at 120 degrees to each other with the ends left long every few feet.  Do NOT over tighten them as they must not distort the cable.

The oversize holes required to get the cable ties in mean you have clearance to put rubber grommets in them to protect the cable at both ends.

It will be quite easy unless you have had an idiot previous owner who has used expanding foam to stop the wires rattling . . . . !!!

130

(3 replies, posted in Sails & Rigging)

Any decent sailmaker can make a main with a  boltrope and  a shelf foot  and  that  allows the draught to be changed as if it was loose footed.  The amount a conventional sail's draught can be changed is considerable anyway and if there isn't enough adjustment range a flattening reef is another option.

A loose footed main is likely to be more highly stressed at the clew than a conventional one.

Don't have that problem! ;-)
Early UK boat so no self draining cockpit.  There is a drain through the transom with a non-return valve to keep waves out that comes out 6" up the aft cockpit bulkhead that is supposed to help if you take a wave in the cockpit, but its a glassed in copper tube with no seacocks.

Unless you have a full cockpit cover to use when the boat is unattended, there is no point in having cockpit drain seacocks.
You'd be better off without them and with double clipped armoured hoze, but your insurance probably expects them to be there.

*YES*.  On our boat, the cooling water, fuel shut-off valve and engine battery switch all get turned off together, without any other distractions in-between, and the key removed from the battery switch. They are all turned on together as well. Woe betide the 'helpful' crew member who does one of these tasks without completing the other two.

Even so there have been a few occasions where the seacock was closed to check the filter and never got reopened . . . Not good!

Also I forgot to mention above that in really heavy weather all unnecessary seacocks should be CLOSED.

The outlet *must* have a substantial glassed in backing plate.  At least 1/2".  The thru hull can be cut down as it is a straight pipe thread, not a taper one, but you must take care not to mar the thread and get the end flat, smooth and parallel.

The pipe loops up to the deckhead, and many would recommend fitting a vented loop (with the vent plumbed to an exterior fitting on the side of the coachroof - not through the side below the gunwale - if you want to avoid both smells and flooding). 

A well and regularly maintained Jabsco with vented loops on the waste and the flush pipe (between the pump and the bowl) can be trusted, while the crew is aboard, not to flood the boat if it is always pumped dry till it bubbles, but not while the boat is unattended for any significant length of time.  As, on a C026 the rim will be well above the waterline, don't worry about leaving it on if you are just popping ashore for a meal but I *ALWAYS* shut all seacocks if I will be away from the boat overnight or longer.

134

(3 replies, posted in Repairs/Modifications/Upgrades)

Well I recently treated myself to a webbing mast climbing ladder that goes up the sail track.  It obviously wont be any use if the reason for the climb is the sail is jammed up, but it makes routine climbs a piece of cake.  You still need a harness and someone managing your safety line on a winch, but that's a single line that is nearly unloaded so no crew muscle required.

I'd only *ever* use a mast winch for climbing in an emergency.  You should have enough turning blocks and at least one halyard long enough to lead to a primary winch. It gets the winchman out from under you so if anything *does* go wrong there is still one person uninjured able to call emergency services and give first aid. Also the bigger winch gives better control and requires less effort, and the horizontal displacement lets the winchman see where you are with respect to the masthead and other mast fittings. Together these factors vastly reduce the chance of a mishap.

If you do have to go up the stick in harbour by 'traditional' means, and its a year or more since the last time, plan on cleaning all nav lights and changing their bulbs while you are up there, and also a top to bottom inspection of the rig, re-doing any anti-chafe tape on spreader ends etc. on the way back down.

I thought the old story was something along the lines of: Spread the beam a bit by jacking the sides apart and (IIRC) plank up the sheerline a bit till the two of them liked the way it looked. 

One would expect quite a bit more volume.  It wouldn't be worth doing that for an inch or two.

Why not find some *reliable* file hosting site (possibly Google Docs, but why not put it in some obscure corner of your own site), put the lines PDF there and link it here?  Its not like there is a significant chance of getting slashdotted . . .

136

(6 replies, posted in Repairs/Modifications/Upgrades)

137

(10 replies, posted in General Questions/Comments)

The Genoa will go on the furler as standard, but the working jib almost certainly replaces it for heavy weather rather than setting on a separate stay.  Except for light weather downwind passages wing and wing you *dont* want to set a jib 'flying' and a permanent stay less than 1' from the furler would be a total PITA.

You can reef by furling by about 30-40% before the sail shape gets so bad you are better off with it rolled right up, so, while in harbour, you hoist then furl the right one for the forecast then hope the forecast is accurate.  Its a pain to do at sea because when you drop the sail, the luff comes totally free from the furler and it has to be fully unfurled first.  Not too bad if changing up, but you *DONT* want to be changing down due to deteriorating weather especially as its a two person job and *someone* has to go right forward to feed the sail into the furler.  I wouldn't take that duty in bad weather without a drysuit and full safety harness. 

I try to stay off the foredeck in heavy weather unless the  foresail is either stowed or drawing on a reach (close to broad). There is a high chance of getting a face full of jibsheet and I heard a distress call a few years back after a crew member on another boat got a loop round the neck.  Dont know if they survived.

With most furlers the head of the sail goes on a swivel on the furler and the swivel is hoisted by the halyard.  It is essential that the swivel goes nearly all the way to the top as otherwise the halyard tends to catch on and wrap round the furler foil and forestay which, if you dont notice, can easily damage the furler and if you force it further can damage the forestay.  If one of the sails has a shorter luff than the other it should have a strop at the head so the swivel hoists fully.

There is at least one older brand of furler that doesn't use a swivel.  Instead it has a block at the top of the foil with a hayard cleated off at the bottom of the foil that turns with it.  As you cant have a bunch of line there with the sail up, the halyard tail is detachable.

I doubt mid boom sheeting offers any performance benefit whatsoever over boom end sheeting with a powerful vang (kicking strap) led aft.  Its definitely harder to trim as the loss of leverage compared to boom end sheeting means a more powerful purchase is needed and extra blocks means a lot more friction.  Also the boom would need to be internally sleeved to handle the load or even completely replaced.  Add the need for a heavier track  car and brackets and the price is going to be excessive.   

It takes the mainsheet away from the helm which is crazy from a shorthanded sailing point of view and no dodger is going to make you extremely reluctant to actually use the new toy for any serious windward work . . . ;-(

Our new heavy weather jib has built in pennants at the head and foot to match the luff length of the regular genoa.  They are continuous with the luff tape

I also specced it to match the sheeting angle with the pennants in  place but that probably wont be possible if going from a deck-scraping light weather sail to a high cut heavy weather sail.

If you fit a pennant at the tack, it needs a slug (slide) in the furler track or a tie round the foil (or if traditional a shackle or hank round the stay) at the tack to take the foot tension otherwise you will get a lousy shape and may even damage the sail.

I agree with the benefits of bowsing down the tack for a main sail and have a three part tackle rigged to the boom at the gooseneck to do so, but would be wary of any such tackle on a foresail.  Having to go right forward to adjust it in heavy weather is not my idea of fun and if led aft you have the disadvantage of an on-deck trip hazard and its also more vunerable to damage.  Just use the winch for the last few inches and all is good.  If you dont have a winch clap a tackle   on the halyard fall and sweat it up.

140

(10 replies, posted in General Questions/Comments)

Ok, first time round 'Pro' assistance can be well worth paying for, but you need to check and inspect *everything* you can before handing the job over to them, and make sure you observe and take notes.

Before my mast was first stepped, I spotted a cracked tang on the masthead fitting for the forestay that the rigger had missed when preparing the mast for storage the previous season and also a toggle below the furling drum with the wrong sized pin that had obviously been that way for a number of seasons.  The toggle was replaced to match the hole size at the bottom of the furler and the one on the stay plate on the bow and the masthead fitting was reinforced and welded.

Inspect the standing rigging as best as you can. It really needs to be off the mast to do it right.  Wearing heavy LEATHER gloves, coil each stay in a fairly large diameter coil and look for 'meathooks' (ends of broken wires).  Any found is an instant fail for that stay AND the same stay on the opposite side which must be assumed to be the same age and had the same wear.  If more than one stay has a broken strand, replace the lot.  Inspect terminal fittings closely. any visible damage or if bent, condemn the stay (unless its a replaceable fitting like a Norseman or Sta-lock).  Remember, wire rigging can look perfect until you bend it and a broken wire end pops out.

Check all blocks and sheaves, lubricate where appropriate and make sure that at least two masthead halyards are in good enough condition to trust with your life when you have to go up the mast.

I also replaced the VHF aerial, mount and lead (they'd lost the wind hawk off it and the mount was loose) and cleaned the lenses, contacts and connections + fitted new bulbs toall the lights up the mast.   Replace the VHF cable if the old one is over 5 years old or of uncertain age or if there is any evidence of wear, damage or corrosion.  The aerial itself is probably OK if it appears to be in good condition and can be swapped out  in 1/2 an hour from a bosun's chair.    Lights should be tested using a 12V battery (or lead from a car cigarette lighter socket) and a lead with clips you can connect to the wires or plugs and an in-line 5A fuse to protect against shorts,

If you know how to use a multimeter (and every skipper should), measure the resistance of every up-mast circuit at the plug or connector  (from the (switched) 12V feed to the 0V return) with the new bulbs installed and record it in your maintenance log.  Its a big help when fault-finding in future to know you *DONT* need to climb the mast!  Also check the resistance to the mast itself.  There should be no circuit. Any under a couple of Megohms has faulty insulation and needs fixing (except the VHF cable which may be grounded to the masthead via the aerial mount, If so it should read under 20 ohms to the mast and no circuit with the connector removed from the aerial and mount.  Record all wire colours, plug pin-outs and connections in your maintenance log.

Masthead instruments cannot be easily checked.  If you can disconnect the masthead unit easily, the cable can be checked wire by wire for shorts and continuity or if you can get the mast heel over your coach roof, you can hook them up and do a functional check.

You are paying  these guys by the hour and if they find any problems will be paying them for repairs.  They will obviously do a standard inspection of anything they rig, but will NOT do preventative maintenance unless you ask for it and having them do everything wont get you familiar with your rig which you need to be for your own safety.  Its worth paying them to check and service (if required) the furler.

142

(2 replies, posted in Site Support/Comments)

143

(19 replies, posted in General Questions/Comments)

What happened?  Limited number of Contessa 26es and how many of our owners are heavy internet users against a tidal wave of spammers.     Regardless of that, I seldom miss reading any genuine posts and check back here every couple of days when ashore.
--
Kazbek  (first year of J.R.'s production).  Thames Estuary area, UK

144

(3 replies, posted in Technical)

Got any photos of Contessas being lifted in slings from a single spreader bar?
A vertical line from the crane hook *must* pass through the C.G.

I don't think you need this info to build a cradle though unless you are putting wheels on it.   You want enough spare strength so that any support can take the full load with the boat tilted say 10 degrees so yo have enough safety margin for bad storms ashore which means you aren't too concerned with the fore/aft load distribution.

You know the CG is somewhere above the bottom of the keel, presumably around 1/3 the way back or so because Jeremy designed the C026 to stand on its keel and is too smart to overload the hollow back end of the keel.  Should be close enough for government work :-)

To remove it I'm fairly sure you don't have to remove the water pump, BUT you *MUST* get the pump shaft to engage properly with the drive gear when you refit it if you don't want to do damage so you'll almost certainly need to take it off anyway.  I suppose you *could* try and engage it with the impeller out and pump cover off, but as its seal to the timing case is an O ring, you'd do better to take it off rather than trash the pump cover gasket.   Refitting is supposed to be done with the pump cover off, but if you make sure the gear is visually aligned with the pump shaft, gently twisting the whole pump will get it to engage and then you can align the holes.

I hope you still have the old pump to refit and check the linkages haven't been distorted.  You can bet you'll need a timing case gasket if you have to go in there. If you do open it,  replace any shaft seals that show any signs of weeping oil.  My camshaft seal was bad and it always had oil on the hand start spindle.

To remove it I'm fairly sure you don't have to remove the water pump, BUT you *MUST* get the pump shaft to engage properly with the drive gear when you refit it if you don't want to do damage so you'll almost certainly need to take it off anyway.  I suppose you *could* try and engage it with the impeller out and pump cover off, but as its seal to the timing case is an O ring, you'd do better to take it off rather than trash the pump cover gasket.   Refitting is supposed to be done with the pump cover off, but if you make sure the gear is visually aligned with the pump shaft, gently twisting the whole pump will get it to engage and then you can align the holes.

I hope you still have the old pump to refit and check the linkages haven't been distorted.  You can bet you'll need a timing case gasket if you have to go in there. If you do open it,  replace any shaft seals that show any signs of weeping oil.  My camshaft seal was bad and it always had oil on the hand start spindle.

I hope you removed the oil filler cap for access to the linkage to get it engaged correctly when refitting?

If you cant unjam the linkage from the pump via the oil filler, you'll need to get inside the timing case.

You *DO* have the workshop manual?
(if not, I recommend googling for: motoren ath yanmar menu)
See chapter 5 for removal of timing gear cover.

You will need to remove the hand start cover over the camshaft end, the pin in the shaft end and the pulley and its key from the crankshaft end.

Its fairly simple once you are in there, and will just be a matter of seeing what part of the linkage you've managed to bend or jam. I doubt the pump is actually defective.

148

(21 replies, posted in Repairs/Modifications/Upgrades)

The problem is that the common failure mode for the  one piece mild steel injection elbow is for the inner sleeve to pinhole near the top and let cooling water impinge on the exhaust passage in the head which sooner or later rusts through to the pushrod galleries and meanwhile the exhaust valve and seat are suffering badly.  I have a head that looked fine until I started digging the crud out of this passage and found it had holed through.  The passage will have to be machined out and a tubular insert brazed in to fix it.  The OEM head was a package deal with new valves already fitted and as I was running short of time I didn't proceed with fixing the old one.

I'd concentrate on avoiding the whole problem by improving the injection elbow.  It shouldn't be too difficult to get a two piece one made up to the same pattern as the OEM one only with the inner sleeve on a separate thinner flange that the flange on the outer tube bolts on top of.  You'll need to talk to a good custom muffler shop for advice on what's going to be most corrosion resistant.

The OEM elbow is definably a wear item and needs a close inspection using a torch and a dental mirror annually.  Also it's crazy to lay the engine up with either the exhaust or the water hose attached to the elbow.  It really needs both removed and fogging oil or similar applied then bag it up in plastic with a fresh silica gel dessicant sachet up the elbow.  Same treatment to the inlet manifold after removing and washing out the foam air filter and make sure both valves are closed and you'll not be needing a new head.   

Water pump problems are a whole other issue.  If it starts weeping it will sooner or later cause serious corrosion of the mild steel oil line directly below it  and then its a matter of luck whether you catch it in time or have it blow under way and seize the engine.  If this line starts corroding have a replacement made up in copper pipe, DONT buy the OEM one! The banjo ends can be reused and brazed on the new line.  Also a sustained drip can result in excessive corrosion of the timing cover and possible loss of the thread in the lower bolt hole of the water pump mounting.  If mine deteriorates further I'll have to get it welded and re-tap the hole.  USE DURALAC on the water pump mounting bolts and I've cut a drip shield from thin polythene sheet that goes under the pump base flange to keep any future weeps off the timing cover and oil line.

The OEM engine mounts are also a disaster waiting to happen and priced like they were gold plated. After-market ones are available which are fuel and oil resistant, fully captive so the engine can't break loose in a knockdown  and also are more compact and make it easier to fit the engine in.  They also are around 1/4 the price!  In the USA an adaptor plate is available to match the OEM mount bolt holes and height for an exact drop in replacement, but I chose to rebuild the beds rather than import a set.

149

(21 replies, posted in Repairs/Modifications/Upgrades)

I rebuilt a 20 year old 1GM10 last winter.  Crankshaft skimmed, new undersize bearings, new rings and a new head. Runs like new for a fraction of the price.  Now I know production has stopped I'll have to look harder for a good used spare gearbox (the old one works fine but is out of spec for wear) and starter.

Think how long it would take to access seacocks in those locations at  sea.  It's not that much work to rip them out and glass up the holes and fit new through-hulls *with* seacocks somewhere where they can be reached without taking up the cockpit sole.  If you cant reach them, they don't get used regularly and then you find they are seized next time you want them! How far back can you comfortably reach beside your engine?

New backing blocks, Seacocks sized to the hoses  rather than trying to match the old holes (which if damaged during removal could well need considerable repair work) and *much* more room to fit them means the job will go quicker and with far less cussing. 

The only reason for deck scupper drains exiting at the waterline is to prevent water stains on the sides of boats that are neglected in some marina.  If you are using your boat often enough and looking after it, you neither need nor want them.  I'd look to see if they can be *totally* removed with the scuppers draining directly overboard.    , otherwise its seacocks in accessible locations again. or if you have to relocate them, then if you move the through-hulls  right up the sides to well above the waterline, you may well be happy with double clipped hoses, no seacocks and tapered bungs for emergency use.  If you are using any sort of plastic through hull, Make sure you have at least one bung that will fit the hole its fitted in!

I wouldn't worry much about  a small diameter, properly installed, good condition threaded drain plug on the side of the keel at the lowest point of the bilge, but if it's really on the bottom, get rid of it!   A previous owner obviously wintered the boat somewhere with a cold climate as a drain plug is usually used where there is a serious risk of frost damage.  Its very little risk unless you have a 'hot' wire drop off into the bilge and it gets eaten by electrolysis.