Monday, January 28, 2013

Sorted.


I wouldn't say I've got a predisposition toward big projects, but it does seem I'm a bit above average at this stage as compared to the rest of the offshore cohort. That blasted engine business a few months ago is what started it all. Now it's the cockpit decking. The latter is not nearly so bad, though, for a number of reasons. I've had the masts off for ten days now and I am well on my way to finishing. Here's the scoop:

After nearly ten-thousand miles of offshore sailing, the mizzen mast, which sits on the cockpit deck just aft of the cabin-house, compressed the decking substantially. The cockpit well- the rectangular area that makes up the lowest part of the cockpit- had begun to separate from the decking. The deck was angling in toward the mizzen. It is a problem that is rampant on Mariners, as the deck in the cockpit was not supported well enough in the original design. On Ardea, the problem got worse and worse with time. In Tonga, I began to notice that the lower shrouds on the mizzen had lost a great deal of their tension, indicating that the mast was moving, albeit very slowly, toward the point of crashing through the deck and into the engine.

Note the sagging. Also the separation to port.


It worried me a great deal for many miles. I was careful with my sail area and tried to keep the pressure off as much as I could. I knew the problem needed to be addressed, but I wasn't quite sure how bad it would be and how I would go about repairing it until I started ripping out the cockpit decking underneath the mizzen.

Easily breaking through to my galley cubby.

I pulled out teak and rotten plywood and support beams until I ended up with this:


The aft beam, about an inch and a quarter wide,
was all that supported the king plank.



Then came time to build it back up again. I used a couple of borrowed car jacks to bring the cockpit well back up to the original level and put in new runners to support it. I then ran a few new beams to support the deck on port, which had been failing due to rotten wood as well.





All of that was very easy. I used two-part epoxy with silica filler to glue in each new piece before screwing it all together. It was only a matter of replacing what had been there before with new, stronger wood.



Then I had to come up with a way to support the deck under the mizzen. The old design had nothing to support the aft portion of the deck except a single athwartships beam; nothing extended to the hull and there was no bulkhead in place for that purpose. So, I ran a couple of good strong hardwood beams down to the thick epoxied engine mounts. I bolted them to the engine mounts and screwed them into the new forward panel of the cockpit well. That ended up being the most challenging part simply because it was so difficult to drill the holes for lack of space; I borrowed a right-angle drill from Len the schooner captain and then ended up buying several 3/8ths inch bits which I cut to various sizes with my angle grinder. That way, starting with the shortest bit, I could drill in some; I took the bit out and put the next one in the partial-hole, fit the drill chuck around it, tightened, and kept at it. Eventually, I had my bolt-holes. Pain in the neck, but so it goes.


Starboard vertical support bolts into engine mount
runners with two 3/8s in stainless bolts.
Then I ran a beam athwartships on top of the new supports after slotting them at the top to carry it. The latter provided new support for the king board- the large piece of wood that sits directly beneath the mizzen step. Incidentally, the piece I got for the king board is a gorgeous bit of timber called purple heart. Shame to cover it up, but I'm glad to know it's down there.

Got my little galley shelf re-built.

That pretty purple heart. 

From there it was simply a matter of laying new plywood decking. I opted not to put teak back in; it costs about $75 per square foot and, though it looks good when it's new, it just ends up being problematic. It's tendency to leak is what led to all of the aforementioned rot in the first place.

More deck removed to port. Plywood added to create
overlap with new decking (for waterproofing).

Instead, I will lay a layer of fiberglass, paint with liquid polyurethane deck paint and put the mast-step back on. It looks a little funny since much of the cockpit deck is still teak, but eventually that will be removed as it inevitably fails. For now, Ardea's cockpit will be two-tone, though the mast and propane housing hide much of that. In the end, cosmetics comes second to functionality.

Tomorrow, a bit of fiberglass and some sanding,
and we'll call it a done deal.
What seemed an overwhelming project for a few quick seconds was in the end pretty straight-forward. I was lucky to meet a few nice people that lent me some tools and some off-cuts of hardwood, so it was actually quite a cheap project as well. In the end, not a whole lot was needed. The timbers, a sheet of plywood, a hand saw, a sander (I used a manual block and an electric sander), an angle grinder (for making flush those pesky brass screws that are in those beams to stay), epoxy, silica filler (glue powder in Kiwi), some fiberglass cloth, and a lot of fasteners. It took about ten days of not-that-hard-working work, though I accomplished a number of side projects in the mean time (fixed the lazarette cover with some of the harvested teak, fixed the settee table, fixed one of the interior hatch covers, got all the rust stains off the deck, cleaned, cleaned, cleaned). It's been productive.

Before. 

After. Oxalic Acid. It's the stuff.

I've got a week left over. Time to dive into the next project. It never ends, but it's great to be knocking things off the list at a good clip. It won't be long before I can cast off these blasted dock lines and find I'm floating again in tranquility at Great Barrier Island or somewhere- wherever- else.

Friday, January 18, 2013

That escalated quickly.

Scallops and Horse Mussels.
I briefly considered bailing and heading back for another day of indolence in the bay at Urupukapuka, but when I looked astern the island itself, as well as the pass through the rocks at the margin of Bay of Islands, had been engulfed in fog. The same dreary clouds were moving to obscure Cape Brett off my starboard bow as I pummeled forward through a nasty chop against a thirty knots breeze. I stayed at the wheel working the waves and spilling the heavy gusts, wearing all my foulies, trying to keep warm. Saltbreaker fought the same battle just ahead of me.


 Bay of Islands.


Urupukapuka
It was Friday, the seventh of December. I had a flight out of Auckland the coming Monday and a fair bit of coast to cover between Bay of Islands and Whangarei in the mean time. The forecasts had been nasty for days- fifty knots in the Hauraki Gulf, easing slightly to the North. We awoke that morning to a relatively decent forecast, though. As we were weighing anchors, the sun was out in the sheltered bay. It was the first phase in what would be a day of remarkably varied conditions. It would seem the Pacific would send a smorgasbord of her finest as we hauled down the coast.

From Cape Brett, I eased the sheets and shot like a rocket downhill under half jib. The chop was short-period and steep, and Ardea was hitting nine knots regularly. She even kept up with Saltbreaker. For a while at least. The sun departed in clouds, then reappeared. The wind got stronger, then lightened up, then stiffened again. Rain came and went. At one stage, as I careened South in twenty-five knots under full jib and a close-reefed mizzen, I looked astern to see a massive and veritably gnarly squall line. I didn't quite believe it at first, but watched the pace of the clouds for a moment and then quickly doused the mizzen and reefed the jib. It hit me with a freezing rain and thirty-five knots. I got on the radio to warn Saltbreaker, but they were a mile or two ahead of me and never got the squall. It seemed the weather had something different for everyone. We agreed, though, that this was excellent sailing. We were having a phenomenal time.

We continued down toward Bream Head, the point around which lay Whangerei. Saltbreaker saw the passing of the front, the wind suddenly changing from northwest to southwest though losing little of its power. For me, though only a few miles away, the front passed with less excitement. In fact, before long, I was becalmed. I laughed to myself at the irony of seeing such a range, a taste of nearly everything the Pacific had mustered over the last ten months. Soon the wind kicked up again. About twenty miles north of Bream Head, we tuned into the vhf weather broadcast (how convenient!) and heard fifty knots still licked points southward. It was early afternoon. We made the decision to head toward Tutukaka and save the last push to Whangerei for Sunday, when the winds would moderate.

This proved a fortuitous choice with this lovely cove like a head of broccoli, small covelets branching out separated by an incomplete isthmus, a few rocks or a sand spit. We anchored in one of the covelets and raved with excitement about the day. We were wind-licked and salty. It was a familiar and fine feeling. It felt like we'd been out on the Bay. Our response was Pavlovian, for we knew there was no greater cap to such a day as a pint and pub food. We piled into Tuerto and scooted across a few broccoli branches towards a marina and the small town, er, village, of Tutukaka. The water was shallow and the Johnson scraped a few times reminding me of the outgoing tide.

In town we found the restaurant, which was under the hotel, which was also the apartment building, which housed the business and the grocery store. Low and behold we soon found friends among the sole other party at the establishment who piled into Tuerto for a tour of our boats whilst we gathered the necessary items for a night on the town. Whangarei, that is. Still at least a half-day's sail away, the city was nontheless a mere twenty-minute drive. Our detour, though pushing me ever-closer to my deadline, was vindicated by the blessing of some great new friends. We spent the following day hanging out in Tutukaka as the weather eased.

On Sunday, Alex and Nick left Saltbreaker at anchor in Tutukaka and boarded Ardea along with our friends Nikki and Carrie. For the first time in a while, I would head out for a day sail with friends and a couple boxes of beer. We beat into a headwind most of the day but the sun was warm and noone complained. It was a long mixture of sailing and motoring up the channel to Whangarei Town Basin, but we made it at dusk. I tied Ardea up to a pile mooring twenty-two hours before my flight was to take off in Auckland.


Bream Head.

The next morning I sorted everything out and moved Ardea to the mooring at which she would spend the next month. I put my fishing equipment, my outboard and all the other valuable pulpit ornaments down below, packed my bags and caught the bus. Naturally, since I sailed to the land of wind, there were a handful of yachties I happened to know on the bus come South from Bay of Islands. I languished in this last fruit of the glorious lifestyle I had led for almost a year.

California. What a place. In a blink my trip Stateside flew by. It was good, in a word. I ate and drank and laughed and lamented. I met my nephew, Cameron, and carried him proudly in the suspenders of my overalls. I enjoyed the great company of my family and a good many friends. I flew East to New York and was so affected by the cold that I forgot the smell of diesel. It was good to be home, if crazy and overwhelming and intense.

I made it back to Auckland and, after crashing on Only Child with John and Nia and Alex for a few nights, reunited with Ardea in Whangarei. I brought her across the basin to a boatyard and pulled the masts off yesterday. Then things really started to get interesting. It is day two of my time tied to this dock next to a boat at which an altercation led to the incarceration of no less than four souls last night. With hammer and chisel I have progressively dismantled with emotional distress as though I were performing surgery on my own child. I have nearly finished the utter destruction of the forward portion of Ardea's cockpit decking and well.  Tomorrow, perhaps, I will begin to build her back again. That boat yards are places of great character and of great characters holds true in the southern hemisphere thus far.

Uhhhh. Moral support welcome.

With any luck, I'll have Ardea put back together again within two weeks, but, as the affable captain of the gaff-rigged wooden schooner on hard-stand nearby says, “Predictions are difficult. Especially regarding the future.”