Six Month Maintenance Summary - New Zealand Edition - The Sequel

As promised in the last maintenance summary, here is summary of the maintenance conducted since we arrived in New Zealand.

Of interest, we have been cautioned not to publish such lists as, in the very distant future, when we may want to sell Fluenta the potential buyers may be scared off because they will discover cruising is actually a fair amount of work.  Perhaps, but the reality is that any complex machine used in the harsh marine environment will need lots of maintenance.  Further, it is not only old boats but even likely more frustratingly, new really expensive boats that need constant maintenance (was listening to stories of an almost new multi-million catamaran that spent most of the season in the yard ...).

What is nice about this list is that there some capital improvements to Fluenta that will make her more pleasurable to live on and sail:

• Rain enclosures:  Peter from South Pacific Marine Canvas did an excellent job designing and building us a rain enclosure around our cockpit.  It is designed so that the boat can be sailed with it partially up and works together with our UV panels.  Peter has logged many miles sailing and was great to work with.  We had been planning this project for several years but waited until we found someone we could trust to do the job.  Liz had bought all the material last year when a canvas shop closed.
• Battery Charging:  Another project that has been on the books for several years.  At anchor we are pretty much energy neutral with our big solar array and wind generator.  Any battery charging shortfall or the occasional battery equalisation is done with our great little Honda 2000 petrol powered generator at anchor.  On windward passages the wind generator steps up to the plate and again makes us close to battery neutral even with our big autopilot (for example, from the ITCZ to the Marquesas we did not need to run the Honda or the engine to charge). Downwind is another story altogether though.  We have used the Honda at sea but it varies between being merely inconvenient to just plain impractical.  Our old alternator set up on the diesel propulsion engine was okay but not optimized for battery charging at low RPM's.  As we cruise at about 1400 to 1500 RPM on the Perkin 4.236 so we are not spinning the alternators very fast.  Our new system has two 120 amp alternators working together controlled by a Balmar 612-Dual regulator.  Using the Balmar belt regulator function I have derated the alternators to reduce the load on them and still get about 155 amps at a high idle.  Perfect for charging our big house bank (940 amp hours at 12V) on passage while still sailing.  As well, we get the maximum charge during the short periods we run the engine to enter and leave anchorages and tight passes.  There is still the stock alternator that charges the separate engine start battery.  This project of course led me look closer at the rest of the system and clean up or replace many of the power busses in the rest of the electrics as well as add new alternator brackets.
• Sink Drain Pump.  Okay, this doesn't sound too exciting but it is ... twice, yes twice we have had departures delayed as the sink drains have failed.  The lovely sink drains that I had sourced in back streets of Mexico and Fiji did not like the fact that they would be exposed to sea water depending on the heel and load of the boat.  Also, as the old system relied on gravity to drain the grey water to the sea a quite amazing ecosystems would grow in the pipes requiring much effort to clean.  In the new system there is a big gulper diaphragm pump that pulls the grey water out of the sink, sends it up and over a vented loop and then down to a thru-hull.  Now no sea water comes back to the sink, nothing appears to be growing in our lines and a failure of the sink drain would not cause the boat to sink.  Of course, now that the sink drains are not exposed to salt water they should also last a lot longer.
• Shower drains.  Really, I do not like plumbing but ... our old shower drain system was crazy.  There was a barely downwards slope to a big grey water tank.  This results in constant plugged lines and a smelly grey water tank that takes up too much prime storage space.  Now we have another diagram pump that pulls the water out of the shower and sends it through a vented loop and overboard.  Now we have more storage for wine and rum and hopefully now I can spend less time unplugging the shower pipes.  We also did away with a float switch so there is one less part to fail.
• Rigging:  Rigging is a lot more fun but the only addition here was to reduce the friction in the system by putting some better blocks in systems that seemed to have more friction that they should.  Not really a capital improvement but we changed how our the vang is rigged to reduce the twisting load on it and replaced some of the tired component.
• Non-Skid: Most of the deck is teak which is great non-skid but I added a bit of non-skid tape in a few areas where I regularly would step on gelcoat.
• Heater: Kind of a funny project since we spend most of the time in the tropics but I recommissioned the diesel heater.  This time last year in New Zealand we were wishing it was working but a combination of better weather and the rain enclosure means we have not used it yet.
• High Water Alarm: It is funny how little projects can make a difference.  Set above our two electric bilge pumps is a independent high water alarm connected to a really loud alarm and bright warning light.  The bigger electric bilge pump also has an audible alarm so we should never need the dedicated high water alarm.  At sea however, after we do a big roll to port, the old mercury filled float switch would set itself off for a short second. This short second of ear piercing, blood pressure spiking sound is not good for ones health even if you know it does not mean you are necessarily sinking (if we are sinking we should have the big electrical pump alarm first and then the high water alarm).  Our new alarm is solid state and has a few second delay so there will hopefully not be anymore false alarms.  Sleep on passage is precious.
• Iridium Go:  Addressed in a previous post.  This is to complement our high frequency radio and Pactor modem.
• Staysail Recut:  We also had the staysail recut to work better in strong winds.  Could be argued that is is corrective maintenance but anyway it will be nice to have this sail working properly.

We also contracted out tasks less this year which is nice especially considering the issues we had last time in New Zealand.  We had problems with the diesel shop (who with prodding fixed the issues under warranty), compass shop (we fixed the issues ourselves but no refund from the company), and worst, the water maker debacle last year (note: recommend sending your Spectra watermaker direct to Spectra in the US rather than risking wasting money with Enertec here in New Zealand).

Even in New Zealand where we have been able to usually buy just the right bolt we have needed improvise a bit.  Wendall and I filed down this set screw (grub screw in NZ) to fit the furler

Checking out the view ... and the rig plus changing out some blocks

Victoria has been splicing up some soft shackles which she has for sale.

Johnathan adding grommets to our RHIB seat bag with help of the kids from Nirvana.

Maintenance to the halyard blocks.  Should be less friction now.

We have replaced a lot of the old wiring this year.  Victoria fits better into the spaces than I do.

Even Benjamin has got into the maintenance game. Here he is fixing one of his cars.  I am in the background replacing yet more wiring.

Here is the output from the spreadsheet.  It is cleaned up a little bit and colour coded as follows (there are a few errors in the colour coding but coloured tables and Blogger do not play well together so I am not going to tempt fate and correct them):

• Green:   Improvements
• Yellow:  Preventative Maintenance
• Red:       Corrective Maintenance 

Date	Maintenance	Periodicity	Category
23-Nov-15	a/p rudder response failure - reset brushes
26-Nov-15	check alternator belt tension	25	engine
26-Nov-15	Oil (100 hrs) - 7.95L of oil	125	engine
26-Nov-15	WM Flush filter - broken bowl and leaking intake		WM
26-Nov-15	burnt wire bundle under alternator - cut out and replaced approx 16 wires. Added conduit plus hose chafe protection
26-Nov-15	panel around SSB
26-Nov-15	propane solenoid
26-Nov-15	pump out engine pan
27-Nov-15	Oil Filter Change	250	engine
27-Nov-15	nmea 2000 power - new cable
27-Nov-15	shower drain wiring - replace bilge pump - rule 800
27-Nov-15	tidy up nmea 2000 connections
30-Nov-15	renew mast boot		rebed
30-Nov-15	Rigging check - NSR		rigging
01-Dec-15	rebed and add insulation - staysail halyard block		rebed
01-Dec-15	rebed mast collar		rebed
01-Dec-15	rebedding - emergency tiller access		rebed
01-Dec-15	rebedding - hyd hose		rebed
01-Dec-15	renew caulking - mast collar		rebed
01-Dec-15	deck wash hose adapter
02-Dec-15	ball bearing block for main halyard		rigging
02-Dec-15	non-skid - dorade trunk
03-Dec-15	check engine hoses	12 month	engine
03-Dec-15	Outboard 15 hpanode	6 mon	outboard
03-Dec-15	outboard 15HP zinc anode replacement		outboard
03-Dec-15	outboard handle and foot		outboard
04-Dec-15	oil leak - oil cooler hoses		engine
04-Dec-15	NZ flag repair
07-Dec-15	RHIB - Tube patches		rhib
07-Dec-15	flag halyard
08-Dec-15	RHIB - remove/replace shackle		rhib
08-Dec-15	check fuel filter bowls	Monthly
08-Dec-15	hull/Prop clean - checked - okay	Monthly
08-Dec-15	Prop/shaft zincs - checked - okay	2 mon
08-Dec-15	vent cap for gas jerry can
09-Dec-15	RHIB - New lines - chaps		rhib
10-Dec-15	watermaker strainer clean		WM
10-Dec-15	check charts for next season plus ipad charts, paper charts, navionics big chip, Coastal Explorer charts
11-Dec-15	engine water strainer	30 days	Engine
11-Dec-15	Engine zinc - replaced	30 days	Engine
11-Dec-15	Oil cooler zinc - change next month	30 days	Engine
11-Dec-15	mainfurl - Grease the grease nipple on the aft end of the spar.	2 Mon	Grease
11-Dec-15	Windlass - bimonthly	2 Mon	Grease
11-Dec-15	Outboard 15 hp grease	6 mon
13-Dec-15	replace reefer strainer - used old spare
17-Dec-15	charts for chartplotter - refund on Cmap and new Navionics XG50
17-Dec-15	Nautical Almanac download - 2016
18-Dec-15	stanchion repair		NSR
18-Dec-15	rebed stanchion port above computer cupboard		rebed
18-Dec-15	rebed stanchion port above fwd galley cupboard		rebed
18-Dec-15	staysail repair/recut		sail
19-Dec-15	remove bad grounding wire to aft lights		electrical
19-Dec-15	replace dodgy splices to port aft ceiling lights		electrical
19-Dec-15	resplice ground wire to port aft reading light		electrical
20-Dec-15	replace port aft reading light		electrical
20-Dec-15	terminal block behind galley - corrosion and burnt connector		electrical
20-Dec-15	ball bearing block for furling line		rigging
20-Dec-15	replace sheave - pole uphaul		rigging
20-Dec-15	15hp outboard throttle cable replace
20-Dec-15	grease outboard throttle cable
21-Dec-15	chafe protection - oil cooler hoses		engine
21-Dec-15	chafe protection - transmission sensor wire chafe protection		engine
21-Dec-15	pressure water pump - replace power wires.
21-Dec-15	Stbd Genasun MPPT - replace
22-Dec-15	Beauchat speargun - new shaft lines
22-Dec-15	cmap marshall is charts for CE - big laptop
23-Dec-15	clean nav laptop fan
27-Dec-15	rebed - window fwd head		rebed
27-Dec-15	check fuel filter bowls	Monthly
27-Dec-15	hull/Prop clean	Monthly
27-Dec-15	Prop/shaft zincs - good - uncovered gunk	2 mon
28-Dec-15	rebed fittings above SSB		rebed
28-Dec-15	rebed toerail outboard of sailing cupboard
28-Dec-15	slice wire outboard of sailing cupboard
29-Dec-15	deck leak - stbd side above tin can cubby		rebed
29-Dec-15	rebed midship cleat stbd side
29-Dec-15	rebed stanchion outboard of stbd book cupboard
29-Dec-15	rebed toerail outboard of stbd book cupboard
30-Dec-15	mock up rain catcher
01-Jan-16	shower drain - not draining
02-Jan-16	WM - plugged intake ?		WM
02-Jan-16	fix battery connection - IR thermometer
02-Jan-16	WM - change prefilter
02-Jan-16	WM - repair intake bracket
03-Jan-16	Battery water - fwd - 60 days	60 days
03-Jan-16	Update PC predict wind
04-Jan-16	MOB light - new bulb		MOB
04-Jan-16	MOB light - new D cell x 5	12 mon	MOB
04-Jan-16	Battery water - aft - 60 days	60 days
05-Jan-16	RHIB - seat bag grommets		rhib
05-Jan-16	genoa furler furling line - replace - 91' at 2.61/m		rigging
05-Jan-16	Bimini - bend frames
05-Jan-16	reglue chafe guards on RHIB
06-Jan-16	engine raw water to pump hose clamps - replace - wire insert rusted		engine
07-Jan-16	anchor shackle - check and replace seizing
07-Jan-16	tighten engine mount bolts - port aft and check others.
10-Jan-16	outboard - clean carb bowl
10-Jan-16	outboard fuel line- replace fuel hose - o ring not sealing
10-Jan-16	propane tank - leak at valve fitting. New fitting ?
11-Jan-16	oil pressure buzzer
11-Jan-16	Sink drain
11-Jan-16	sink drain pump. New Jasbco diaphragm pump
12-Jan-16	van - 12 V socket x 2		van
13-Jan-16	replace aft head light with LED		electrical
13-Jan-16	rebed deck hardware - kids cabin - padeyes		rebed
13-Jan-16	rebed pole up haul block		rebed
13-Jan-16	rebed fittings in fwd passageway - liferaft cradle and three padeyes
15-Jan-16	check forestay extrusion for tight setscrews - tightened top one.
17-Jan-16	Engine zinc - looks good	30 days	Engine
17-Jan-16	Oil cooler zinc	30 days	Engine
17-Jan-16	clean grey water tank and bilge
18-Jan-16	pickle WM		WM
01-Mar-16	predictwind app for ipad
06-Mar-16	reglue inside veneer fridge lid
07-Mar-16	Engine zinc	30 days	Engine
07-Mar-16	Oil cooler zinc	30 days	Engine
07-Mar-16	Force 10 oven knobs
07-Mar-16	Prop/shaft zincs	2 mon
08-Mar-16	rope clutch - mast		ap
08-Mar-16	vang - replace lower fitting		nsr
08-Mar-16	Vang - twist ?		rigging
08-Mar-16	vang clevis pin - new cotter pin		rigging
08-Mar-16	Battery water - aft - 60 days	60 days
08-Mar-16	Battery water - start battery - 60 days	120 days
08-Mar-16	Outboard 15 hp gear oil	6 mon
08-Mar-16	teak deck clean
09-Mar-16	alternator spike suppressors - Balmar		engine
09-Mar-16	bilge clean
09-Mar-16	repaint and mark anchor chain
10-Mar-16	anchor roller - replace port side roller with cylinder or cone ?		NSR
10-Mar-16	bimini - water proofing	6 mon
10-Mar-16	clean water tanks	12 mon
10-Mar-16	Pressure water filter	4 mon
11-Mar-16	BCD pressure valve - take apart button and service		dive
11-Mar-16	Diving regulator service		dive
11-Mar-16	aft cabin stbd reading light - new bulb		electrical
11-Mar-16	clean corrosion from #1 house bank alternator positive to fuse box		electrical
11-Mar-16	Alternator regulator MC612-Dual		engine
11-Mar-16	clean reefer strainer and bowl	2 Mon	reefer
11-Mar-16	rain enclosure for cockpit		sewing
11-Mar-16	replace reefer strainer
11-Mar-16	windlass cover - add front snap
12-Mar-16	clean ground leads for house bank alternators		electrical
12-Mar-16	new alternator - Bosch 120A - alternator #1 - no output, burning smell, glows !		electrical
12-Mar-16	new alternator - Bosch 120A -- alternator#2 - replace - low output		electrical
12-Mar-16	alternator x 3 and starter - check wiring	125	engine
12-Mar-16	check alternator belt tension	25	engine
12-Mar-16	mainfurl - Grease the grease nipple on the aft end of the spar.	2 Mon	Grease
12-Mar-16	Windlass - bimonthly	2 Mon	Grease
12-Mar-16	Windlass Service - preseason service - every 6 mon	6 mon	Grease
12-Mar-16	Outboard 15 hp grease plus corrosion spray on throttle cables	6 mon	outboard
12-Mar-16	Navionics app
12-Mar-16	Wind gen - increase V max to 14.4
13-Mar-16	RHIB Tubes - patches		rhib
13-Mar-16	replace MOB light		safety
13-Mar-16	hull/Prop clean	Monthly
13-Mar-16	Mildew clean - cabin and cockpit
14-Mar-16	anchor shackle - check and replace seizing	3 mon
14-Mar-16	clean DST sensor
18-Mar-16	15hp throttle adjustment ?
18-Mar-16	Inspect lifelines	12 month
18-Mar-16	lifeline chafe guards adjust
18-Mar-16	speargun - new lines
20-Mar-16	check fuel filter bowls	Monthly	Engine
20-Mar-16	Fuel Filter - Primary	250	engine
20-Mar-16	Fuel Filter - Secondary	250	engine
20-Mar-16	Transmission oil change (every 400 hrs or annually)	400	engine
22-Mar-16	corroded wire - energy monitor		electrical
22-Mar-16	check alternator belt tension	25	engine
22-Mar-16	alternator belt - engine bank
22-Mar-16	alternator regulator - change absorption time and FFL
22-Mar-16	alternator regulator - change to Deep Cycle
22-Mar-16	alternator regulator - check by removing sensors
22-Mar-16	alternator regulator - check oil pressure signal
22-Mar-16	Battery water - fwd - 60 days	60 days
22-Mar-16	chartplotter - clean NMEA0183 connection
22-Mar-16	chartplotter - more slack in cable
22-Mar-16	clean engine pan
22-Mar-16	oil drain pump impellor replacement
22-Mar-16	shower drain system improvement - jabsco gulper pump
22-Mar-16	WM overflow - add a bracket
23-Mar-16	alternator adjustment brackets - Balmar		engine
24-Mar-16	alternator x 3 and starter - check wiring	125	engine
24-Mar-16	heater - test (Half Moon Bay)		heater
24-Mar-16	Autopilot - check bolt torque	3 mon	Lazerrete
24-Mar-16	autopilot brush and hyd fluid check	6 mon	Lazerrete
24-Mar-16	Lubricate steering cable	6 mon	Lazerrete
24-Mar-16	Steering cable tightness - check quarterly	3 mon	Lazerrete
24-Mar-16	heater wiring - repair
24-Mar-16	replace a/p brushes - new ones 18mm, old 6.5 mm
25-Mar-16	alternator - move ground wires x2 to battery negative
25-Mar-16	Binnacle bolts and duralac on binnacle
25-Mar-16	compass leak
25-Mar-16	compass light wiring
25-Mar-16	vang attachment - new bolt at boom
26-Mar-16	clean or replace ground terminal post in battery compartment		electrical
26-Mar-16	clean positive post		electrical
26-Mar-16	high water alarm with time delay like water witch		electrical
26-Mar-16	remount heater fuel pump		heater
26-Mar-16	Lubricate steering chain	6 mon
26-Mar-16	voltage drop in ground
28-Mar-16	battery connections clean - aft
29-Mar-16	start bank alternator shunt - replace		electrical
29-Mar-16	alternator common ground - clean
29-Mar-16	alternator shunts -clean and replace with power post
29-Mar-16	Honda generator - dynmea start cord plus "marinized" with stainless steel bolts etc
30-Mar-16	diode isolator - move and new wires
01-Apr-16	a/p top hyd fluid		ap
01-Apr-16	Autopilot - check bolt torque	3 mon	Lazerrete
01-Apr-16	Lubricate steering cable	6 mon	Lazerrete
03-Apr-16	covers on positive lugs x2 in engine compartment
03-Apr-16	dent in paint port fwd - from mooring
03-Apr-16	honda generator - overspeed ?
03-Apr-16	mom8 attachment'
03-Apr-16	Outboard 15 hpfuel filter - clean	6 mon
03-Apr-16	Outboard 15hpsparkplugs - new	6 mon
05-Apr-16	Genoa furler - replace liner on bottom bearing, drill and tap new fastening to 8 mm. Make teat screws x2, add 10 mm grubscrew to hold drum down		rigging
06-Apr-16	saloon table strut bolts - short with thumb area
07-Apr-16	dent in fibreglass - companionway
07-Apr-16	HF ant wire - renew - SSB GTO15 connection - battery lug to bulldog clamp. Fill lug with solder and cover with heat shrink	12 mon
07-Apr-16	redo crimp on aft port battery ground - 90mm2 to 8 mm terminal
07-Apr-16	sup pump - new handle
08-Apr-16	heater ducting repair		heater
09-Apr-16	battery connections clean - fwd		electrical
09-Apr-16	new positive bus instead of power post		electrical
10-Apr-16	calibrate barometers
10-Apr-16	patch old SUP
12-Apr-16	Iridium Go		Iridium
12-Apr-16	update Iridium Go Firmware		Iridium
13-Apr-16	fix sea boots - heat gun
14-Apr-16	check fuel filter bowls	Monthly	Engine
14-Apr-16	engine water strainer	30 days	Engine
14-Apr-16	Engine zinc	30 days	Engine
14-Apr-16	Oil cooler zinc	30 days	Engine
14-Apr-16	Honda Generator - Fuel Filter	6 mon	Generator
14-Apr-16	Engine coolant change 13L	12 mon
14-Apr-16	port aft scupper blocked
15-Apr-16	Honda generator - Clean air filter	6 mon	Generator
15-Apr-16	Honda generator - oil change	6 mon	Generator
15-Apr-16	rain defector on dodger
18-Apr-16	furler - check top bearing		rigging
18-Apr-16	port spin block replacement		rigging
18-Apr-16	rig check - upmast
19-Apr-16	Honda Generator - spark plug CR5HSB NGK	12 mon	Generator
19-Apr-16	Essence of Salts for heads
19-Apr-16	stove - aft burner thermocouple grounding - cleaned contacts and added 3xwashers to protect surfce
23-Apr-16	add longer floater line to anchor rode		anchor locker
23-Apr-16	extend anchor rode rope to bitter end		anchor locker
23-Apr-16	new nav laptop
23-Apr-16	RHIB – new dingy tank. Install new fittings
23-Apr-16	Vesper - AIS USB isolation
24-Apr-16	portable watermaker – annual maintenance	12 mon	Safety
24-Apr-16	Review Ditch Bag contents	12 mon	Safety
24-Apr-16	panel under stbd electric winch
24-Apr-16	SUP mount install
24-Apr-16	table temp repair
26-Apr-16	Iridium Go - copy emergency contacts to contacts from Sat Phone		Iridium
26-Apr-16	confirm emergency numbers in Satphone	12 mon	Safety
27-Apr-16	new sea strainer for engine raw water		Engine
27-Apr-16	Overhaul winch - Anderson	12 mon	winch
28-Apr-16	check engine mount nuts	50	engine
28-Apr-16	engine air filter check	125	engine
28-Apr-16	engine water strainer	30 days	Engine
28-Apr-16	v berth hanging locker - won't latch
03-May-16	Iridium satphone activation		satphone
03-May-16	reregister satphone with GEOS SOS		satphone
04-May-16	dodger clean
05-May-16	check fuel filter bowls	Monthly	Engine
05-May-16	check fuel filter bowls	Monthly	Engine
05-May-16	Battery water - aft - 60 days	60 days
05-May-16	clean speed sensor
05-May-16	hull/Prop clean	Monthly
05-May-16	Prop/shaft zincs	2 mon
06-May-16	rain enclosure - fixes
07-May-16	Alternator regulator - buzzer goes off		alternator
07-May-16	alternator regulator - set deep cycle flooded, max batt temp 43, max alt temp 100, absorption 3 hrs, min volt low		alternator
07-May-16	alternator x 3 and starter - check wiring	125	engine
07-May-16	check alternator belt tension	25	engine
07-May-16	top up oil at 4803.6 topped up from just over half way to full on dip stick		Engine
07-May-16	Replace Iridium Go antenna adaptor		Iridium
09-May-16	mainfurl - Grease the grease nipple on the aft end of the spar.	2 Mon	Grease
09-May-16	Windlass - bimonthly	2 Mon	Grease
09-May-16	Watermaker carbon filter	6 mon	WM