Winter Projects on The Gaffer

[bigboy]

Try island bunker Oils. Never had any problems

[The_Gaffer]

Try island bunker Oils. Never had any problems

Who are they Bigboy, do you have contact numbers?...will they come to msida Pontoons?

[camkev]

Island Bunker Oil Ltd.    10A Il-Moll tal-Hatab Marsa 21225526
 

21312490
23451000
21316244
21316243
21317433
'Warehouse', Triq tal-Lampat, Gudja  21225531
21806384
   

[The_Gaffer]

Island Bunker Oil Ltd.    10A Il-Moll tal-Hatab Marsa 21225526
   

21312490
23451000
21316244
21316243
21317433
'Warehouse', Triq tal-Lampat, Gudja  21225531
21806384
   

Thank You!!.  Pass/gest umli u ta' minn iffahru. 

[bigboy]

Try island bunker Oils. Never had any problems

Who are they Bigboy, do you have contact numbers?...will they come to msida Pontoons?

Yes they will come to msida pontuns

[The_Gaffer]

project Update

Engine Update
Quick update on the Engine.  The new injectors were fitted on the engine today.  Next all injectors were calibrated used a dial gauge (to calibrate common rack)  and a laptop connected to the engine ECU to calibrate fuel command flow.  Next the fuel system was primed.  Starter connected to a battery, fresh water hose pipe connected to the water pump,  one half turn of the starter motor, and the engine fired up!!!!
As soon as the engine came to life, a very very small amount of white smoke was visible coming out from the exhaust.   After the engine was running for 30 seconds, even that dissapeared.  This happens as the fuel going into the combustion chamber of of each cylinder at initial startup is still cold.  However, as soon as the fuel being feed to the injectors goes through the pre heater fitted on the engine, then the temperature for ideal combustion is perfect, and the result is what it should always be, a smokeless diesel engine.  We allowed the engine to run on the test bench for about 30minutes, still connected to the laptop, with a simulation programme running in the background to simulate normal running under load, high revs, low revs, idle speed, every possible scenario  the engine can encounter, which are all simulated on a specialised programme to test engines.  No smoke, engine is very quick to respond, and idles perfectly at 635rpm with a fuel burn at idle of 2.7lts/hr. 
Conclusion, Engine is running perfectly once again.  Tomorrow I'll pick up the engine from the mechanic, drive down to the boatyard, and prepare the engine to be fitted on The Gaffer on saturday!

[alfadelta]

Prosit Joe, looks like everything is under control! ejja ha imorru ghal alungi

[The_Gaffer]

Yes Antoine.  We're at the final stages of completion now, boat should be ready on schedule for launching in May.

[The_Gaffer]

Project Update

Radar Arch
Guys, thank you so much for the contacts.  In the end I opted for Medway SS works.  Medway are doing some work for a colleague of mine on his boat in the boatyard, so its convinient for both of us, since they're already on site. 

Instrument Panel
The new instrument panel will be fixed on Saturday.  After carefully extracting it from the mould, its been cut to size and to accomodate the engine panel. 

Engine
The engine is now at the boatyard.  Mundinu sanded (using a wire brush drill bit and drill) all flaking from the gearbox, and on Saturday we'll apply a primer coat and then spary paint the gears and touchup the engine spray.  I'll also change the oil and fuel filters, fill her up with oil, change the engine coolant, and hopefully put the engine in its bay on Tuesday.  The racor filter has had a great job done on it by Guido99 at MIL.  The filter body was blasted using a special compound, then electro galvanised and spray painted with Ameron's Amerlock 400 epoxy paint.  Thank you Guido99 .  This has been now fixed into position and all whats left is the copper fuel lines.

Deck Flooring
As previously posted, the previous owner of the Trojan had cut away the recess over the deck flooring which prevents water from spilling into the bilges.  Thus, whenever I hosed down the deck, or it rained, water would spill down into the bilges.  I've rebuilt this using balsa wood and covered with fibre cloth and epoxy.  Hopefully water will now just drain away from the decks

[The_Gaffer]

Project Update

Engine
The engine was fully serviced, with an oil and fuel filter change, oil change, engine coolant changed, all zinc anodes changed, and the paint touched up.  On Saturday we placed the engine inside the Gaffer's engine bay onto the engine mountings.  On Tuesday I wil align the engine to the prop shaft, and reconnect all wires, fuel lines, engine control and gears' cables and sea water inlet.  Once that's done, we'll start up the engine and run it for a while to see that everything is in tip top shape and top up engine oil and coolant.

Engine Controls
Fitted in new Morse teleflex engine and gears controls and cables on both Helm stations on the Gaffer.  Bought these controls from a friend of mine who replaced them with electronic controls for his Bertram 33.  I still have two complete control units left, and they're in excellent condition, having only 2 seasons in service.  So if anyone's interested in them, visit http://www.maltapark.com/item.asp?ItemID=696573  for more info.

Radar Arch
The radar arch should be ready this week and fitted in place.  Once that's in place, will fit on the VHF antennas, TV antenna and anchor light.

Our journey on upgrading the Gaffer is nearing completion.  What started out in mid-December as a planned project to redo the Gaffer's interior,upgrade the electronics, redo DC wiring and engine/injector service finished up with new unit injectors and remapping of the engine ECU, new raw water pump, timing belt and belt tensioner, overhauled turbo and after cooler, cleaned the heat exchanger, and finally a paint touch up.
The interior is practically all new now, including the teak trimmings.  Electronics upgraded as planned.  Glassed in the keel and bilges and finished off with a paint job.  New 240v AC Honda Genset fitted underdecks with  heat extractor and exhaust.  Over 100 odd jobs that needed looking into, new radar arch, improvised deck flooring to facilitate water flow from decks, ect, ect, ect.

[alfadelta]

Prosit Joe, The Gaffer seems to be on track for the 'Oris Alungi Competition'

[The_Gaffer]

Yes Antoine, the boat's on track to be launched in 3 weeks time.  Time enough to make some setup tests (trolling) and get some deep bottom fishing done. 

[The_Gaffer]

Project Update

After 5 months of planning, refitting, upgrading, renewing and replacing, The Gaffer will launch as scheduled on Saturday 15 May.  Sporting new upholstery and furnishings, new DC and AC wiring, new electronics, a new radar arch, new injectors and upgraded engine, and 1001 other upgrades and refits.  

What can I say, its been a very fruitful 5 months, working together with Ray (Mundinu).  

I need to say a big thank you to a few people here who have contributed to this successful project.

I'll start with Ray (Mundinu).   Ray has been a constant help throughout.  Never missing a day of work on the boat, always encouraging and pushing for the desired result.  Ray has been my guiding light throughout this successful project, always backing me up, challenging my suggestions, and providing encouragement when we ventured into unknown territory.  Ray, thank you so much my friend.  The Gaffer would not be where it is today without you.

Ripard Larven Ripard (RLR) - Thank you Darius and Matthew for your generous support and encouragement, The Gaffer is now fully equipped with the latest GPS,fishing and autopilot technology by Raymarine provided by RLR.

Holma Boat Storage - Leli at Holma boat storage was a constant help and supporter, opening up his workshop and providing professional tools which surely made the difference on the whole project.  Grazzi Leli!!

Steyr motors gmbh - Steyr provided excellent customer service when it came to trouble shooting and upgrading of the unit injctors.  Steyr were also instrumental in providing a manufacturer's discount on new unit injectors.  Thank you Steyr.

Medway Marine Stainless Steel Works - Thanks guys for your prompt service and great customer support.  Medway worked on the improvised Radar arch, and the job is excellent.

Guido99 - Thank you for the work (blasting, plating and paint work) on the Racor filter body and mounts.

Shanook - Thank you for the switch panel labels.

Skip - Thanks for your continuous support, photos of works in progress and visit.

To all members who have endorsed their support on this thread and elsewhere throughout this project, I say thank you.  Your encouragement has left the desired effect.


Tomorrow The Gaffer gets a full waxing and teflon coating in prep for the hot summer, the bottom gets a coat of anti-fouling, and on Saturday 15 May, its launch day.


Will post pics which we intend to take tomorrow of all the work done on The Gaffer

Last but not least, I must mention an unsung HERO in all this, my wife Alexia, who had to put up with my absense every weekend and public holiday since we started work on the Gaffer last December.  Alexia supported me throughout this project, listening to the difficulties, let-downs, and triumphs Ray and myself went through while on the job.  All this, when I could have spent quality time with her and the kids, especially with the kind of job I have, where I spend most of my working days overseas on business.  I know she won't read this, but I had to acknowlege that fact!

[bigboy]

Welldone great project !

[malvizzu]

Good luck for the new season!!