Maintenance Log 06-2004 to 10-2004
6-23-04
Separate main batteries back to banks 1 & 2. BANK2 is connected to the system; BANK1 is idle. Do not have enough cable to connect to system. This will be a check out: BANK1 13.08 (at battery) BANK2 13.19 (at battery) Link 2000 is in float mode, will change settings, then turn on reefer and see how this does for a week.
6-24-04
2000 GPH bilge pump was not working. Checked wiring. Needs work, but pump is bad. Will replace in Port A.
6-27-04
Installed in-line noise filter on the power input of ICOM 502 VHF radio. This has fixed the loud hum problem that used to be present. Replaced light switches on the lights in the storeroom. A switch was bad in EACH receptacle! !! Cleaned out main strainer that is on the input of raw water manifold. Replaced small strainer on the pump input for after air conditioner. Checked battery BANK1 12.89 VDC
6-29-04
Followed wires for the failed instruments from aft cabin to binnacle to nav station to boom gallows. The autopilot in the binnacle worked fine if the output wire was disconnected. Found problem to be soldered splice had broken on the wire from the binnacle to the nav station at the nav station end. Repaired splice and all instruments are working. By the time I got it all back together, it was 1800.
6-30-04
Took off main engine raw water pump and housing. Took off fuel pump cover plate on block. As I suspected, it was the cause of an oil leak. Made gasket and put back on block. The drive wheel on raw water pump and injector pump were loose. Took raw water pump apart and discovered that 7 or 8 impeller blades were cracked, but not broken off. Replaced impeller and built one good pump with parts to make a good coupling. Hopefully, used good set screws and used thread block. Reassembled back onto engine. Also, wiped down engine to try and track down oil leak.
7-01-04
Started engine and verified water flow. After warm up, ran up to 1500 rpm. Discovered oil leak. A screw on the after end of injection pump in block ?? Also, noticed that raw water pump moves when running. Had to take raw water pump off of engine to get to bolt. Replaced bolt with better head and put back in using thread lock. Also, attempted raw water pump alignment during re-installation. Tightened holts on main engine front housing. Seems to be a source of oil leak.
7-02-04
Started main engine and verified water flow. Ran engine @ 600 rpm for 10 minutes. Ran up rpm to 1500 for 30 minutes. Temp did not get up to 180 degrees. I guess it got to approximately 170 degrees. Shut down engine. No evidence of oil leak on front housing, screw in block or rocker arm cover. Seems to be good news. Started wiring of replacement bilge pump.
7-03-04
Finished wiring 2000 gph bilge pump with silicone and heat shrink. Switched BANK1 battery to Heart system as BANK2. Old BANK1/new BANK2 12.95. Old BANK2/new BANK1 13.13. At 1534, battery voltage at 12.40. Turned on battery charger. At 1615 did not look close. Charger is showing float @ 12.90 volts. “Something ain’t rite!” Installed new 5-year 2000 gph bilge pump. Works great. Washed out bilge twice. Left ½ quart of HEB degreaser in bilge for overnight. Will wash out again tomorrow.
7-07-04
Linked batteries back up. Please see REPAIR LOG for 7-7-04. Appears we still have a problem. Sent email to Heart Interface for advice.
7-12-04
Swapped in spare Shurflo fresh water pump. New one failed, so put in the old one that I had rebuilt.
7-14-04
Took off Lighthouse anchor windlass. Motor is locked up and there seems to be some play in the shaft. Sending both off to the factory for repair or replacement.
7-15-04
Removed jib, main, and mizzen sails from boat. Jib was packed up and put in ‘Little Room’. I replaced Dutchman monofilament line on mizzen, and put it in the ‘Little Room’. Main sail has some repairs for the sail maker. Will haul there on 7-19-04.
7-16-04
Removed and emptied water and fuel jerry jugs. Cleaned up deck and lines. Generally getting all loose gear off boat to start repair projects.
7-17-04
Took off first piece of forward cap rail on starboard side. This cap rail will have to be repaired, after all of the holes in the hull to deck joint are filled and repaired.
7-19-04
Removed bow pulpit, bowsprit and bobstay. Re-bedded and reinstalled bow pulpit and bowsprit. Moved dolphin striker so that it is at 90 degrees from bow; also had to shorten PVC protective pipe. Epoxied together the broken cap rail.
7-20-04
Put plugs into broken cap rail. Sanded same.
7-21-04
Worked more on broken cap rail. Cut out piece for aft trash bins.
7-22-04
Put first coat of paint on trash bin holder. Worked on broken cap rail. Removed second piece of forward cap rail on starboard side and covered exposed holes in the hull to deck joint with tape.
7-23-04
Filled holes and bad places in the hull to deck joint where second piece of forward cap rail was removed from the starboard side. Ran repair errands.
7-24-04
Worked on second piece of cap rail. Filled and sanded holes in the hull to deck joint where second piece of forward cap rail was on the starboard side.
7-25-04
Worked on computers.
7-26-04
Worked on second piece of cap rail. Re-bedded and reinstalled first piece of forward cap rail on starboard side with 5200. Took apart Shurflo pump for freshwater system. Motor appears to be bad.
7-27-04
Worked on second piece of cap rail. Worked on trash can piece of wood. Worked on pump parts to extract shaft from raw water pump. Put second spreader light on main mast. Adjusted rigging. Moved main mast forward to align spreaders. Also, greased lower turnbuckles and added washers to clevis pins. More to finish tomorrow in the rigging.
7-28-04
Did not work on rigging. Had to wait for 5/8” washers. Verified operation of new PA speaker. Checked mizzen VHF antennae and it seems to work OK. Aft VHF radio does not seem to work fully. Will get Mike to check it out. Verified leak in garage and head is coming from eyebrow.
7-29-04
Cleaned up Lighthouse parts. Worked in shop. Removed third piece of forward cap rail on starboard side, and filled in holes and area at edge in the hull to deck joint. Removed port cockpit hatch to fill with Smith’s epoxy.
7-30-04
Cleaned third piece of cap rail and put plugs in all holes. Cleaned inside of cockpit hatch and put on two applications of Smith’s epoxy. Cleaned more Lighthouse parts. Sanded some of the holes and area in the hull for third piece of cap rail.
7-31-04
Hopefully, did final cleanup and epoxy on third piece of cap rail. Did two more applications of Smith’s epoxy on cockpit hatch. Put on second piece of forward cap rail on starboard side. Looks good! Started removing aft starboard eyebrow. Cleaned out holes and covered with tape. Definitely the source of many leaks.
8-01-04
Cleaned up and re-bedded aft starboard stanchion plugs on cap rail. Started repair of aft starboard toe rail break. Put primer coat on port cockpit hatch. Finished sanding hull/deck joint for third piece of forward cap rail on starboard side. Marked areas under aft cabin bunk for tank storage. Applied first coat of paint remover.
8-03-04
Started disassembly of outboard motor to replace water pump. Applied first coat of Easy-poxy on port cockpit hatch. Put on third piece of cap rail on forward starboard side. Repaired floor (parque deck) in aft cabin. Put in 5 of 7 SCUBA/Oxygentank mounts in aft cabin.
8-04-04
Worked more on outboard motor. Applied second coat of Easy-poxy on port cockpit hatch. Started fabricating hangers for bolt cutters. Put in last two tank mounts in aft cabin. Put plugs in handle on forward dingy box.
8-05-04
Finished up fairing in tank mounts in aft cabin. New Duraglass does not sit up as well as older. Not enough cream hardner. Will put off painting tank mounts for a few days.
8-06-04
Worked on bolt cutter brackets. Got all bolts out of outboard motor, but head of one twisted off. Cleaned, sanded and caulked outboard aft starboard cap rail. Finished repair of broken toe rail on starboard aft. Started cleaning and sanding inboard aft starboard cap rail as preparation for caulking.
8-07-04
Finished bolt cutter brackets and installed bolt cutters on holding tank bulkhead in garage. Fabricated bracket for pepper spray in galley, overhead.
8-09-04
Put first coat of Cetol on cockpit hatch. Installed pepper spray bracket in galley. Finished installing washers and grease on main mast rigging. Must finish both back stays.
8-10-04
Installed hasps on dingy deck box. Put on second coat of Cetol on cockpit hatch. Installed check valve in port PAR/Jabsco bilge pump outlet. First one leaked so had to get second valve and install it..
8-17-04
Put third coat of Cetol on cockpit hatch. Worked on line launcher brackets and pieces for through-hull. Cleaned raw water strainer manifold and strainers for air conditioning and reefer. Removed first piece of port forward cap rail.
8-18-04
Installed cockpit hatch. Worked on dingy motor. Started cleaning cap rail and hardware on first forward port cap rail piece.
8-19-04
Cleaned first cap rail piece and epoxied in plugs to fill holes. Worked on outboard. Finished cleaning parts. Need to clean stainless steel. Worked on water maker plans. Removed second forward port side cap rail piece.
8-20-04
Sized boxes and items for water maker. Started cleaning second piece of port side cap rail. Filled in holes on hull-to-deck joint for first and second pieces of forward port cap rail. Installed shotgun mount.
8-21-04
Sanded plugs on first piece of cap rail and put in “side” plugs. Finished cleaning second piece of cap rail and epoxied in plugs. Cleaned top and bottom of aft cabin wooden hatch and put Smith’s epoxy on top of hatch. Worked on outboard motor. Checked fittings of water maker. Moved Bruce anchor to aft line locker with no problem. In aft gas locker, moved propane and to outboard locker. Stern anchor line plus dingy gas tank fit in center section. Decided on pad eyes on masts for awnings.
8-23-04
Finished first piece of port cap rail. Epoxied in side plugs on second cap rail piece. Got outboard apart … really needs pump kit. Put Smith’s epoxy on bottom of aft hatch and cut and inserted a piece of Structoglass in bottom of hatch. Cut hawse pipes for aft deck box. Verified straps and hardware for aft cabin tanks. Sanded and ground on hull-to-deck fittings on port side. Measured and cut hawse pipe holes in aft deck box. Installed trash can racks.
8-24-04
Drilled and countersunk hawse pipe fittings for aft deck box. Nearly finished sanding down second cap rail piece on port side. Sanded top and sides of aft cabin hatch and applied first coat of Cetol. Cut and fitted straps for aft cabin tanks. Also sanded and smoothed plates for tanks. Installed hawse pipes in aft deck box. Installed new gas line and hold downs for trach cans. Finished sanding hull to deck surface for fist and second cap rail pieces.
8-25-04
Put second coat of Cetol on aft cabin hatch. Finished sanding second cap rail piece. Installed first cap rail piece on forward port side. Removed third forward port side cap rail piece. Removed raw water pump from engine.
8-26-04
Put third coat of Cetol on aft cabin hatch. Cleaned third cap rail piece and installed top plugs. Took shaft out of raw water pump. Took three raw water pump shafts to Van to fix and to drill out Delrin. Removed Shurflo freshwater pump and replaced with new pump. Removed reefer 12 VDC motor and replaced with spare. Reefer motor and freshwater pump are off to Rusty for check and rebuild.
8-27-04
Put fourth coat of Cetol on aft cabin hatch. Worked on getting water maker parts together. Put side plugs in third cap rail piece. Installed second cap rail piece on forward port side. Lifted stanchions on aft and port side. Removed all bronze caps. Removed more of eyebrow on starboard side.
8-28-04
Cleaned bronze caps. Put fifth coat of Cetol on aft cabin hatch. More epoxy on third cap rail piece. Pieced together aft cabin screen frame. Picked up electronic parts, parts for bronze caps, and outboard parts. Put spare freshwater pump back together. Installed aft VHF and confirmed operation. Repaired aft shower sump.
8-30-04
Put sixth coat of Cetol on aft cabin hatch. Sanded third port cap rail piece. Cleaned outboard parts. Worked on screen parts. Put second coat of Smith’s epoxy on large anchor(fisherman) parts. Al Shattuck helped me install third port cap rail piece. Cleaned area for bronze caps on port side and stern. Installed and sealed all bronze caps. Put port and stern rail back the way it was.
8-31-04
Sealed Structoglass with sealant on aft cabin hatch. Painted large anchor(fisherman) parts Kelley green. Worked on screen parts. Installed spare fresh water pump to replace new pump that pops breaker. Will replace at West Marine. Removed Autohelm computer to take to Mike with fluxgate compass for repair. Started cleaning cap rail seam on port side of stern.
9-01-04
Worked on aft cabin hatch, second coat of paint. Worked on screens. Worked on outboard. Finished cleaning outside seam on aft port side. Masked off and put in sealant, and cleaned up.
9-02-04
Worked on screen. Worked on water maker. Got matched sets of belts for water maker motor/pump. Put pad eye on mizzen mast for awnings. Filled eyebrow holes on port side and removed and filled eyebrow on starboard side.
9-03-04
Worked on aft cabin screen. Worked on water maker bed. Worked on aft cabin wooden hatch.
9-04-04
Installed aft cabin wooden hatch. Removed port main salon hatch for rebuild. Installed wooden barrier under work bench/over holding tank, for better storage. Installed “T” on aft name board. Installed "W" & "A" on port forward name board. Filled eyebrow port aft. Removed remainder of eyebrow.
9-06-04
Cleaned out main salon hatch and applied one coat of Smith’s epoxy on hatch. Worked on water maker. Filled in all remaining holes on eyebrow. Put stern anchor on, and put rode in aft box.
9-07-04
Installed and repaired instruments and autopilot computer.
9-08-04
Cleaned out main salon hatch and put Smith’s epoxy in top. Fitted pump and motor for water maker. Moved electrical parts for ice maker and started sizing water maker parts in store room. Started installing ice maker parts.
9-09-04
Put Structoglass in top of salon hatch. Final fitting of pump and motor for water maker. Brought water maker deck over to boat for fitting. Made switch panel for ice maker switches. Finished sanding eyebrow holes. One more application of filler should do it! Sized up deck for water maker. Worked a little bit on ice maker.
9-10-04
Put outboard together. Cleaned out outboard water tube. Picked up anchor windlass. Worked on panel for ice maker controls. Worked on water maker deck supports.
9-11-04
Started outboard – pumped water like crazy!! Put Structoglass sides on hatch, and corner sealant. First coat of Cetol. Worked on water maker deck supports. Worked on windlass control to move to dingy deck box.
9-12-04
Second coat of Cetol on hatch.
9-13-04
Put outboard back onto boat. Third coat of Cetol on hatch. Cut pieces for water filter installation. Worked on supports for water maker deck. Installed piece of Structoglass under head deck.
9-14-04
Fourth coat of Cetol on hatch. Worked on water maker deck supports. Worked on main engine raw water pump. Applied Agent Orange (dye) on nav station auto pilot bracket. Installed Lighthouse windlass.
9-15-04
Fifth coat of Cetol on hatch. Worked on through-hull drip rings. Worked on water maker deck supports. Installed wiring for nav lights. Moved wiring for windlass remote. Hopefully, will finish the wiring tomorrow.
9-16-04
Sixth coat of Cetol on hatch. Worked on through-hull drip rings, and completed manufacture. Second coat of Cetol on auto pilot mount. Worked on water maker deck support. Finished installation of windlass, motor, and remote cable in forward dingy box.
9-17-04
Seventh coat of Cetol on hatch. Third coat of Cetol on auto pilot mount. Worked on water maker deck mount. Scraped and sanded mount and put primer coat on mount. Repacked forward dingy box.
9-18-04
First coat of white paint on hatch. Fourth coat of Cetol on auto pilot mount. Worked on water maker – first coat of top paint. Worked on ice maker mounting. Repaired forward sump and air condition drain line.
9-19-04
Second coat of white paint on hatch. Fifth coat of Cetol on auto pilot mount.
9-21-04
Masked off hatch and installed poly-sulfide in seams. Cleaned raw water strainer hoses and manifold for air conditioners and reefer.
9-22-04
Mounted nav station ST6000+ auto pilot. Mounted motor and pump of water maker on water maker deck. Folded all three awnings. Put reef ties in mizzen sail, and mounted sail on boom. Worked on garage storage. Put reef ties on main sail and replaced Dutchman mono-filament lines.
9-23-04
Worked on drawer for galley. Epoxied shelf supports in drawers, and one coat of primer. Repaired starboard nav light that had wire pinched under base. Installed rebuilt hatch in main salon. Put barnacle and CQR anchors back on boat.
9-24-04
First coat of white paint in galley drawer. First coat of Cetol for shelf in galley drawer. Cut out trash compactors. Cut piece of wood for passerielle. Fit small bulkhead for top of holding tank. Measured for shelf in chemical storage locker in garage. Cleaned bilge with bilge cleaner. Verified operation of all four bilge pumps.
9-25-04
Second coat of white paint in galley drawer. Second coat of Cetol for shelf in galley drawer. Put coat of Smith’s epoxy on trash compactors. Worked on bulkhead for top of holding tank, and shelf for chemical storage locker. Cut all-thread for passerielle.
9-26-04
Put primer coat on trash compactors and bulkheads for top of holding tank and chemical shelf. Worked on USB to serial connector. Put coat of Cetol on shelf.
9-27-04
First coat of white paint on trash compactors, and on bulkhead for top of holding tank and chemical locker shelf. Installed genoa on roller furling. Moved genoa halyard to port sheave. Installed main sail. Helped Al Shattuck.
9-28-04
Second coat of white paint on trash compactors and on bulkhead for top of holding tank and chemical locker shelf. Put together galley utility drawer. Worked on cockpit leaks. Worked on wiring water maker, and worked on shelving. Worked on ice maker. Put main sail cover on.
9-29-04
Went after leaks in cockpit. Ran water into engine panel area. Started leaking in galley. Removed gauges, and tore out glass and insulation. Also ran water on starboard side of cockpit hatch. Got the leak! Sealed drain holes with silicone. Worked on water maker area.
9-30-04
Worked on new arrangement for Avalon grill. Installed new man-overboard pole. Worked on water maker area.
10-01-04
Got new Avalon grill installed and checked out. Filled engine panel area with resin and glass to stop leak in galley area. Worked on water maker area.
10-02-04
Finalized water maker area. Installed one of three filters. Worked on shop and Little Room. Worked on main boom reefing blocks.
10-03-04
Put Smith’s epoxy on water maker cover parts. Finished installing water maker filters and installed 3-way valve from 12 VDC pump to wash down/water maker. Reinstalled engine and generator gauges, and checked out.
10-04-04
First coat of primer on water maker cover parts. Installed shelf in chemical locker. Worked on mount for “Hummer” grill (as the Avalon has been named).
10-05-04
Put second coat of primer on water maker cover parts. Worked on ice maker wiring. Moved shelves from shop to Little Room.
10-06-04
First coat of top coat on water maker cover parts. Cleaned shop. Started to remove wooden floor from cockpit.
10-07-04
Worked on re-work of Hummer grill mount. Worked on wiring and plumbing for ice maker, and plumbing on water maker.
10-08-04
Worked on shop clean up. More rework on Hummer grill mount. Worked on plumbing for water maker. Tested fresh water to water maker filters - small leak. Worked on wiring and plumbing for ice maker.
10-10-04
Second coat of paint on water maker cover parts. Worked on final part of Hummer grill mount. Replaced fitting on water maker filter, and retested. Works OK. Put potty lid holder on boat. Started wiring for carbon monoxide alarms. Worked on wiring for ice maker, and plumbing.
10-11-04
Worked on wiring and plumbing for ice maker. Also ran refrigerant lines for ice maker. Tried to get connector on ice maker to work with mate – no go. Got water maker cover parts installed. Still have to get low pressure output valve and input valve installed. Finished removing floor in cockpit. Reamed out holes and put lots of Smith’s epoxy into the cockpit floor and the area around the main mast deck supports.
10-12-04
Worked on ice maker wiring. Went to Grainger, Cox’s Hardware, and Wilco Supply trying to get high pressure parts for water maker – no go. Must make drawing and send to Great Water, Inc., to order parts.
10-13-04
Installed ice maker connector. It is ready to go except for refrigerant lines. Put store room back together. Fixed door in galley dish area. Worked on door for air conditioner and ice maker – does not fit properly.
10-14-04
Worked on door for ice maker. Connected carbon monoxide alarms – one in mid-cabin, one in main cabin, and one in aft cabin. Cleaned up and marked other wiring.
10-16-04
Glassed binnacle to deck and pads for binnacle supports. Put stand-offs for SSB antennae to back stay. Replaced back stay PVC cover. Fixed aft shower sump.
10-17-04
Installed new light on port mizzen spreader. Sanded cockpit floor, and put marine filler around binnacle and binnacle support pads. Did some work on the rigging.