New Hatch Fitted

I met Bruce at the boat early on Tuesday 16 June, which was the one dry day before the advent of several days of heavy weather. 

Conceptually the bedding down of the hatch on Sikaflex 291 then screwing it down would be straight forward and fast, but the job took about three hours of hard work by both of us.  It was imperative that the hatch not leak and Bruce is a master at that sort of work.  I provided the support and some surprisingly good suggestions. 

Bruce applying Sikalfex 291 sealant

Our first task was to drill the new holes for the hatch and fit all of these screws.  The marks for the new holes had to be precise and the selection of the drill bit diameter had to be perfect because the 20 screws holding the hatch down had to bite well into the wood and be drilled straight enough to achieve flush counter sinking.  Once we had dry fitted the hatch we removed all of the screws, lifted the hatch out of the way, and Bruce got to work with the caulking gun.  He knew from experience how much Sikaflex 291 to lay down with minimum cleanup. (Had it been been me, I would have overdone it with the sealant and spent probably hours cleaning up the resultant mess.)  We then screwed the hatch down, spent a few minutes cleaning up, then stepped back to look at the result.

The Master showing the finished product

We were both happy with what we saw, which to me appeared to be as close to perfection as possible. 

But that is not the end of the project.  The hatch was originally installed with bolts followed by a perimeter of wood to support the ceiling, rendering it impossible for those who followed to use bolts again without removing that securely glued in perimeter of wood.  We have used screws to make it easier for any future hatch replacement.  However,  Bruce has made the sensible suggestion of bolstering that wood perimeter with thickened Epiglue, and I was to replace an incredibly rough block for screwing in one of the four teak discs covering the access to the deck winches (which don't exist: the two forward positions are used for deck pad eyes and the rear ones are not used).  I have made the required new block and after I have fitted it Bruce will visit the boat for the Epiglue work then to help  me with the 2-man job of fitting the ceiling panel into position.  After the ceiling is fitted  into position it will be left to me to fitting all of the ceiling panel screws then the wood trimming.

Wood perimeter preventing access to hatch thru bolts

Router OK

My plan was to allow the router to dry out in the garage for several weeks and perhaps longer.  I would have preferred to allow this drying to take place before drenching the interior of the router with Inox but I was afraid that this would result in one or more parts of  the unit to seize up due to corrosion.  This forced me to apply the Inox treatment as soon as I returned to my house only 3 days after the soaking at the bottom of the marina even though this risked the trapping of moisture under the Inox (even though it is advertised to dissipate moisture, but I am a worry-wart by nature).  This turned out to be a wise decision because initially I could not get any movement when trying to plunge the router down.  I managed to free the plunging mechanism after 30 minutes of patient work with judicious use of a hammer and plenty of Inox. 

However, I became impatient with the wait and a week later got the bright idea of forcing warm air through the unit with a hair drier.

Blow Drying

Rescued router at right

It didn't take long to set up the system on Saturday morning, with the drier directed into the cooling vents at one end of the router.  After satisfying myself that there was warm air egressing from the other end of the router I  set the drier to "low" and left it do its work.  Forty five minutes later I returned to find the router warm as toast.   That afternoon I returned to the garage and gave the router another full hour session of drying.  On Sunday morning I threw caution to the wind and gave the router a final 1.5 hour dose of drying - caution because I  did not want to risk damage from prolonged overheating.

That afternoon my friend Reg arrived to witness the power-up trial.  The test bed was an extension cord connected from a power point inside of the garage to the router which was outside on the brick driveway.  The RCD on the electrical panel would surely prevent an electrical explosion but I wanted to be prepared for anything.  I couldn't even be sure if the router switch was working correctly, so the first step was to set the router switch to Off then throw the power point switch to On.  All remained quiet so while holding the router down with one hand I threw its switch to On ... and the router spun up as though nothing had happened.  A week later week later I spun it up again with no problem.  So far so good, and only time will tell if there is incipient corrosion that will  manifest itself later.  But for the moment I have two Makita routers, a brand new 1800 rpm model and the rescued 3600 rpm  model.

As I wrote in a report to my friends, Never Give Up!

Cabin Hatch Replacement

The task of replacing the original Lewmar cabin hatch with the new Vetus Magnus MAG 5038 SL hatch has been a difficult one.

The first problem was that the new hatch with cutout dimensions of 507 x 377 mm were slightly larger than the existing Lewmar hatch cutout of 504 x 368 mm.  Bruce and agreed that the solution was to use a router on the existing wooden perimeter to accommodate the larger footprint. As luck would have it, I had a visit from Paul, a practicing carpenter, at the exact time when I needed advice.  He told me that using a router free-hand was out of the question if we wanted a good result, and his suggestion was to produce a jig or pattern with the required dimensions which would provide a guide and platform for the jig.

To that end I did a surprisingly good job of producing the jig from a sheet of 6mm marine ply, with the dimensions within 2mm of the required cutout.  For the radii of from memory 43mm for the corners I found the air filter fitting of one of my masks that was close enough at 45mm.

Section of Cabin Ceiling Removed

New Vitus hatch ready next to opening to be routed

Starting jig saw run for the jig

Jig (with dimensions of new hatch) ready for router run.

I've making the sometimes difficult boarding of Pachuca since 2005 with as far as I can remember no loss of anything overboard, which is amazing given the huge transfers of provisions, tools, materials, etc that I've made over the years.  My first failure didn't involve something as inconsequential as a spanner or perhaps a torch, but rather my prized, little used, Made-in-Japan Makita 3600 rpm router.  I won't go into the details, but it went into the salt water drink into about 3 meters of salt water.  Skipping the details, a dedicated and generous member of the sailing club staff dived into the frigid winter waters and retrieved the router.  I soaked the router for the entire day and after keeping it in the boot of my X-Trail for several  days was able to completely drench the router inside and out with Inox lubricant, which on top of all of its claims, is non-conductive.

But I could not wait for the slow process of drying out with what I judged a 50-50 chance of recovery and purchased another Made-in-Japan (that is very important to me) Makita 1800 rpm router which was similar to the one that had fallen into the drink.

I had trouble finding a router bit that had a bearing at the top to ride along the edge of the jib with the cutting edges below and would have given up, but Bruce never gives up and working together we managed to find the bit at a place that stated "We don't stock many router bits but the ones we have are over there". It was a small 6.5mm/quarter inch bit and I had to figure out how to use a supplied 1/4 inch collet for the smaller bit.

After the hours of preparation it was Show Time to do the cutting, and Bruce did the router work while I provided the support.  The result was outstanding: neat, clean, and generous, and the new Vitus hatch dropped easily into its new home.

We then took a break while I applied 2-pack undercoat and topcoats to the wooden perimeter to host the new hatch.

Sometime during this period I was forced to protect the boat from an expected "10-year" storm event which turned out to be accurate with a piece of 6mm marine ply over the hatch opening.

Ready for 10-year storm. 

On Show Day we were forced to accept that the narrow gap between the wooden frame glued in to support the ceiling and the frame to support the hatch was too small to allow the fitting of the nuts to the bolts that we had procured.  It was a case of the builders  fixing the bolts to hold down the hatch then gluing in the ceiling supports and thereby making it impossible for those who followed to replace the hatch by either temporary  removing the ceiling support wood work (a difficult and destructive job) or abandoning the use of  bolts and using screws instead, relying on the Sikalflex 291 sealant to do the "heavy lifting" of holding the hatch down against the onslaught of wind and waves.  I was OK with that except that the many existing holes in the bed perimeter resulted in the problem of half-holes being presented where we wanted to drill for the new screws.

Gap too small for putting nuts on new bolts

Hatch opening routed, painted, and waiting for filling holes

We decided to fill in all existing holes with "Epiglue" and to that end Bruce used his expertise to mix a batch of Epiglue, thicken it with special thickening material,  then load it into a syringe that we purchased for the procedure.  He then injected two syringes full of the material into the existing holes while I watched from below and told him that the Epiglue was coming out of the bottom of the holes.

We were then chased off by the advent of another weather front, and the state of play now is that we will meet on Tuesday and finally bed down the new hatch.

The deck photo shows the setup to keep the interior of the boat dry during an expected "10-year" storm that lived up to expectations.  The sheet of 6mm marine ply covers the hatch opening, lashed down at each corner, with three containers of water, themselves tied down, on top of the sheet.  The measures worked very well and I found the interior to be bone dry when I returned to the boat after the storm.

Router soaking in fresh water