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.