Malta Fishing Forum

Main => General Discussion => Off Topic => Topic started by: The_Gaffer on November 27, 2009, 08:48:42 CET

Title: Winter Projects on The Gaffer
Post by: The_Gaffer on November 27, 2009, 08:48:42 CET
Well Guys, yesterday The Gaffer came out of the water, hauled to Holma Boat storage, got its bottom cleaned and power washed, ran the engine for 20 minutes flushing with fresh water, and now she's ready for some major improvements/maintenance.

Engine (Steyr 246 high power Turbo marine diesel engine)

Some of you who have been fishing on The Gaffer may have noticed the white smoke coming out of the exhaust when the engine is idling.  The Steyr 246 is a common rail diesel engine with six electronic/mechanical injectors.  There is no main diesel pump, as each injector is electronically controlled (via ECU) and the common rail is set to operate the injectors accordingly.  That white smoke is a result of unburnt fuel at idle position.  Spoke to the Steyr authorised mechanic and agreed that the injectors are in need of calibration.  In fact, the mechanic stated that during a recent course that he attended at Steyr's facilites in Austria, my engine, yes the heart and soul of The Gaffer, was discussed in great detail with Steyr engineers.  This is the result of the excellent relations I have with Steyr Motors in Austria.  Well, for this to happen, the engine has to come out, and hauled to the mechanic's garage.  Fingers crossed that the injectors only are in need of local calibration, and there is no need to have the injectors shipped to the Steyr facilities for cleaning, electronic calibration and testing.  Steyr Motors are adamant that this job is only performed by them, as they have the patent on these injectors!.  Steyr have provided the necessary tools and equipment to the authorised mechanic in Malta to perform the calibration, and now, following the course, the knowhow!.  While the engine is out, might as well change the timing belt, the alternator and fresh water pump drive belts,  and get the coolers, sea water heat exchanger and intercooler inspected.  

New AC/DC Wiring  

After 30 years in service, I feel that the AC/DC wiring setup of The Gaffer needs renewing.  I just ordered a new DC 16 way circuit breaker panel by Blue Sea Systems, and since the engine has to come out anyway, will proceed to rewire all the AC/DC installation of The Gaffer.  Been doing some shopping in Malta for Tin coated marine grade wire and connectors.  Went to Strand electronics, who have marine grade wire and connectors by Anchor Marine, but prices are on the highend.  Will pursue the search in Malta, however I already have a UK source which sells at a much cheaper price.  

Inside Cabin Teak/Upholstery

Again, 30years have taken the toll on the cabin upholstery, and since some of the DC wiring passes on top of the cabin upholstery, well, might as well renew that too ;).  Already have a plan how the new upholstery will look like.  The cabin will be a light soft cream colour, with stainless trimmings and spotlights.  The teak too is faded and needs replacing.  This will be my toughest job, as I intend to change all wood panels inside.  

New Electronics

The Gaffer will be sporting new electronics, GPS - Fishfinder equipment for 2010.  I've opted for the Raymarine C90 Wide coupled to a 1KW module trasducer.  The equipment is scalable, so in the future, I will add the radar, overhead and under water cameras and AIS.  

The Hull

The Gaffer's hull is definitely in need of:
1.  A professional cut and polish ......or......
2.  A paint job.

This is where I required expert help.  If any of you out there know of someone who is professional at his job and can determine whether a cut and polish will restore the shine to the Gaffer's hull, please let me know.  Alternatively, if it is determined that the hull requires a paint job, then suggestions on spary painters are most welcome.  I have already chosen the paint I'll be using, which is Interlux Perfection marine paint.  Colour: white...(but that marine blue still haunts me)

Well guys, that's the job list for this winter, and its the reason why the Gaffer was put on the hard so early this year.  I cannot but mention my trusted friend and partner Mundinu, who was there to help out yeaterday, and has already pledged his full support for the upcoming works.  A true friend indeed.
Title: Re: Winter Projects on The Gaffer
Post by: Perla 165 on November 30, 2009, 18:34:58 CET
jalla il gid king mela nistaw nedlu li se jkolna " the gaffer" gdid man :). proset u risq al pjantijit tijak
Title: Re: Winter Projects on The Gaffer
Post by: blueskip on December 02, 2009, 19:05:44 CET
Sounds like you wont be getting much change out of a 100 euro note after that lot Gaffer :o I think the lift out & power wash on their own would cost more than my old tub is worth! Anyway the fishing is better here in the winter, well nowadays we dont get a summer anyway!
Good luck with the refit it will be some vessel when its complete I envy you!
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on December 03, 2009, 10:26:28 CET
Blueskip:  The lift out and power wash was completed on Thursday, Mundinu and myself did that as soon as the boat was in the boat yard.
Saturday, spent a day dismantling all connections to the main engine, while mundinu busied himself inside the cabin tearing down the old upholstery.  We also managed to dismantle all the electronic equipment from the driving console, and took off the side panels in the cockpit. 
Hopefully, on Saturday, we'll take out the engine, and start cleaning the bilges. 
Title: Re: Winter Projects on The Gaffer
Post by: skip on December 03, 2009, 13:02:09 CET
Holy S**t you guys don't waste any time! Suprised to read you've already got all that done!
Title: Re: Winter Projects on The Gaffer
Post by: shanook on December 03, 2009, 13:33:08 CET
yo Joe if u find any fish in the bilges DO NOT COOK IT as it might be a health hazard............u have been warned.
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on December 14, 2009, 10:14:12 CET
Quick update on The Gaffer project:
Saturday 12 dec the engine came out of the boat.  Took us some manoeuvering as the space between the cookpit floor and cookpit ceiling is only 6 feet.  We had to get the crane jib inside that space and then slowly, bit by bit lift out the engine.  Finally, when the engine was inside the cookpit, we moved the boat away from the engine, and the crane could then lift out the engine away from the boat. With the engine bay clear, we started stripping away the wiring, which sadly, still looks new after 30 yrs!!...
The new DC distribution panel (16 way) and Miniature Curcuit Breakers are on their way from the US.  I've sourced marine grade (tin coated) connectors and lugs from a reputable firm, Anchor Marine, and still deciding on the wire.   All connections will be heat shrink sealed for added moisture protection.
Meanwhile, we've already started applying coats of clear varnish to all the interior teak trimmings.  The outside teak we'll varnish with 2 part epoxy based varnish, for durability.  
The boat now looks very bare, no upholstery, no panels, no engine; just bare fibreglass.  We'll be attending to a water leak we found from one of the railing bolts.  Water seaped in and did some rooting away to the underlying wood.  this has already been removed and will be replaced. 
Still a long way to go, but the winter looks promising!
Title: Re: Winter Projects on The Gaffer
Post by: Perla 165 on December 14, 2009, 20:28:49 CET
joe any pic of d engine? u fuq ix xolijit li adejin:)
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on December 15, 2009, 08:09:26 CET
Ghandek ragun Perla.  Will try and get some taken this Saturday....
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on December 15, 2009, 10:08:06 CET
Another Update:  Shopping around

Yesterday did some shopping around for teak panelling and marine plywood.  Could not find any outlet which supplies teak panelling over marine plywood, however, from Pace & Mercieca found the thin teak panelling (formica) and from James Camilleri Wood supplies found the 10 X 5 marine plywood.  So, I'll just have to stick both together with glue and start from there.  
Looked around for the water tight marine grade plugs and sockets, and found a good source from the Nanni agent, located at the Zebbug Bypass.  This plug and socket is completely waterproof and rated at 16A.  Ideal for electric reels and Kalamari submerged lights!!
Still pondering  ??? on the inside cabin lights.  Been searching the web and found numerous options, from 12v halogen spot lights to the sexy 2 colour LED's.  The LED's are quite expensive, coming in at around €60  :o, while the normal halogen spotlights are €15!.  I need six  :-\.....
The inside cabin upholstery will be a light biege, which will contrast beautifully with the blue cushions and carpet.  Light blue marine themed curtains will compliment the cabin.


Thats all for now folks... ;) ;)
Title: Re: Winter Projects on The Gaffer
Post by: chrifene on December 15, 2009, 10:29:20 CET
I think that Halogen spot lights vs LEDs emit more light. On the other hand LEDs are cool are very nice.

A few weeks ago I was reading and watching some videos about underwater squid lighting and I saw this video and found it a very good idea for those who own a boat (I don't) -> http://www.youtube.com/watch?v=rnUARp2iKfw. Take a look at the video at about 1:02.

Anyway goodluck mate & hope to see the before & after pictures soon :).
Title: Re: Winter Projects on The Gaffer
Post by: benri on December 15, 2009, 10:32:34 CET
You may wish to try http://www.euromarineshop.eu/ for your lights. They will ship to Malta as I just ordered a couple of rod holders. These are their shipping rates

"We have inserted a new table for shipping in Malta if you or your colleagues need something:
up to 5 kg. euro 21,
5-10 kg. euro 28,
0-15kg. euro 35, 1
5-20kg. euro 43

by air with italian mail service."
Title: Re: Winter Projects on The Gaffer
Post by: camkev on December 15, 2009, 10:37:06 CET
Thajjar Joe forsi taqbad klamar  ;)
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on December 15, 2009, 10:55:08 CET
Issa nigi nghid lilek ta!!!.....

Kont ghadek b'subajk fhalek u tigri bil-harqa int meta kont naqbad il-hut jien!!!!....tghid mhux ser nigi niehu parir minghandek!!!
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on December 15, 2009, 10:57:31 CET
Thanks Benri!!
Title: Re: Winter Projects on The Gaffer
Post by: twoutes on December 16, 2009, 21:23:54 CET
Good luck with your restoration work....sounds like a major one.
Some before/after shots would have been interesting for us all to see.
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on December 18, 2009, 08:04:10 CET
Twoutes:  Thanks mate, will try and get some taken tomorrow.
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on December 21, 2009, 09:18:01 CET
Project Update:

Continued stripping out all wiring on The gaffer, and all wiring now is finally out.  The cockpit console is now bare of all electronic equipment, engine console and switches, to be replaced with new upgraded Raymarine C90 Widesceen coupled to the Raymarine DSM300 1KW airmar 260 transducer.  An additional Raymarine remote autopilot to use when up on the flybridge will compliment the new look!.  

(http://maltafishingforum.com/talk/gallery/3/318_21_12_09_10_01_04.jpeg)

The engine is lying out of the bay inside the garage, when after the new year it will be trabnsported to the Steyr Authorised mechanic for injecdtor calibration and timing belt replacment.

(http://maltafishingforum.com/talk/gallery/3/318_21_12_09_10_05_01.jpeg)

All inside cabin upholstery has now been removed, and we'll start with the rewiring of all 12v DC equipment and lights.  This job will start probably this Saturday, as I need to finish all wiring before starting the new cabin upholstery


(http://maltafishingforum.com/talk/gallery/3/318_21_12_09_10_08_16.jpeg)
Title: Re: Winter Projects on The Gaffer
Post by: skip on December 21, 2009, 11:36:20 CET
Prosit Joe and Ray (P.S. Arranged pics for you!)
Title: Re: Winter Projects on The Gaffer
Post by: Destination Sea on December 21, 2009, 16:37:22 CET
 You have quite a big job ahead. Plan in advance and you get the job done smoothly.awguri joe.
Title: Re: Winter Projects on The Gaffer
Post by: twoutes on December 21, 2009, 23:15:27 CET
Thanks for the photos.
It looks like you're progressing nicely there.
In regards to the remote auto pilot you mentioned...one of my friends has one set up in his boat here, and he uses it at the back of the boat while we are backing up on a fish sometimes when there is no crew. He does get some interference sometimes from other boats causing the motor to increase revolutions. Not a huge problem while out in blue water, but may cause an accident if used to dock your boat at the marina.

Keep up the good work.....and more photos please  ;D
Title: Re: Winter Projects on The Gaffer
Post by: guido99 on December 23, 2009, 07:30:26 CET
Prosit Joe.... now since you've pulled the engine out im sure you'll want to clean up any rusted parts such as motor mount brackets etc. I think this is where i can contribute to your project, while I might not be much help in upholstery or wiring i can certainly help when it comes to rust removal and corrosion protection ( grit blasting, arcspray metallisation and pigmented epoxy coatings). I can only do this work at my premises so you would have to remove the parts and deliver them to me. I am currently on shutdown and will return to work on the 4th January
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on December 23, 2009, 08:57:21 CET
Thanks Guido.  I would like to have some parts go through that process, I'm thinking about the back engine mounts, the shaft coupler, and the rudder tiller.  No amount of sanding and recoating with hammerite has managed to defeat the rust, maybe your method works best. 
                xxxxxxxxxx-------------------------------------------xxxxxxxxxxxxx

Yesterday I recieved the Blue Seas DC circuit breaker panel, and the additional Anchor Marine Circuit Breakers from the US.   The idea is to wire up the circuit in such a way that each circuit is protected by the CB before going to the switch panel, and current is controlled via the switch panel to load :

http://www.westmarine.com/webapp/wcs/stores/servlet/producte/10001/-1/10001/146632/377%20710%201630/712//Primary%20Search/mode%20matchallpartial/80/0?N=377 710 1630&Ne=712&Ntt=&Ntx=mode matchallpartial&page=CategoryDisplayLevel1&Nr=AND(Record Type:PRODUCT,Store:WESTMARINE)&isLTokenURL=true&storeNum=5002&subdeptNum=9&classNum=348 (http://www.westmarine.com/webapp/wcs/stores/servlet/producte/10001/-1/10001/146632/377%20710%201630/712//Primary%20Search/mode%20matchallpartial/80/0?N=377%20710%201630&Ne=712&Ntt=&Ntx=mode%20matchallpartial&page=CategoryDisplayLevel1&Nr=AND(Record%20Type:PRODUCT,Store:WESTMARINE)&isLTokenURL=true&storeNum=5002&subdeptNum=9&classNum=348)


Title: Re: Winter Projects on The Gaffer
Post by: guido99 on December 23, 2009, 17:03:19 CET
Ok then, pm me when you have removed the parts you need done.
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on January 05, 2010, 12:43:46 CET
Project Update:

Work continued on the Gaffer even during the festive holidays.  All removable panels covered in Teak laminate have now been delaminated and relaminated with a cherry-wood laminate.  The job was tedious, difficult and requires tons of patience.  With a blow lamp, we seperated the old laminate from the wooden panels.
Using the wooden panels as masters, we proceeded to pencil outline the cherry wood laminate to the correct sizes, leaving a few mm on each end.  Now for the interesting part.  I have never cut laminate before, but was advised that a very sharp chiesel would do the trick :-\....bullocks.... >:(...it doesn't.  So, onto the internet, goggled laminate, and found out that a good Stanely knife would do the trick.  Which it did ;D ;D

Preparation includes applying a thin layer of special formulated glue to both wood base and laminate.  Allow it to set for about ten minutes, bring both pieces together, and align.  Easier said then done.  Well, we did manage to glue all the panels together, and left them to set for 24hrs.
Now for the trimming part. I had read on the internet that the best way to trim the laminate to size was to use a small hand router with a special bit that actually trims the laminate to the edge of the wood without touching the wood, so, off we went in search of this blessed router...most tool shops were closed for the festive season, and none had this small hand router.  So, putting on my thinking cap, I decided to try trimming the extra laminate using my electric planner, which is high speed and rotates at approx 3000rpm.  Presto!!!!! ;D :D :D,  It worked, then to finish off with a fine metal file to remove the csharp edge. 

So we now have a professional finish on the laminated panels in Cherry-wood ;)

In the meantime, I prepared the inside cabin ceiling with new stips of marine board to accomodate the new ceiling upholstery, changed some marine plyboards that looked worn out, and installed new supports for the heads ceiling. 

Just finished ordering all electrical connectors, heat shrink tubing, butt connectors, and a professional crimper all all made by Ancor Marine. 
Will post some before and after pics of the wood panels   
Title: Re: Winter Projects on The Gaffer
Post by: kris on January 05, 2010, 14:41:02 CET
well done joe you're moving at a very fast pace!
Title: Re: Winter Projects on The Gaffer
Post by: robby017 on January 05, 2010, 14:54:52 CET
keeping a close eye for an early alungi season like last year ;)
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on January 06, 2010, 16:23:31 CET
This is a schematic diagram of how I intend to wire up the new 12V DC Distribution panel to the switches and DC equipment on board The Gaffer.  The Panel has 16 Micro circuit breakers with different Amp rating to accomodate different loads.  Some circuits are wired to the the switch panel while others go direct to source load.  Since The Gaffer also has a flybridge, I also need to supply a 12V DC to the FB, and from the terminal block slave  circuits for navigation lights, search light and bilge pump pilot lights.  
Title: Re: Winter Projects on The Gaffer
Post by: Perla 165 on January 06, 2010, 18:08:17 CET
hmmmm i like this type of wrk ;)
Title: Re: Winter Projects on The Gaffer
Post by: Perla 165 on January 06, 2010, 18:11:21 CET
ek andu sir ix xol bigg ;) al white sensation :P
Title: Re: Winter Projects on The Gaffer
Post by: bigboy on January 06, 2010, 18:20:35 CET
Mela sihbi :) Bhal daz zmien sena hemm se jkun xolok inti taddi l wiring ma kullimkien :)
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on January 06, 2010, 19:09:15 CET
Ikollok bzonni ghal wiring jew pariri fuq DC, Bigboy, no problem, nigi jien.

English Translation
You need any help on DC wiring Bigboy, no problem, I'm available
Title: Re: Winter Projects on The Gaffer
Post by: bigboy on January 06, 2010, 19:19:22 CET
10x Joe :) Qed tara bert mela fej ma tasalx inti issaqsi l gaffer u jejdlek!!!
Title: Re: Winter Projects on The Gaffer
Post by: Perla 165 on January 07, 2010, 09:36:35 CET
ghajnuna u parir min and kulhad tajbin big ;)
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on January 09, 2010, 17:55:28 CET
Project Update:
Jsut finished a good day's work on the Gaffer today. 

We delaminated the Heads/shower door and applied a new laminate sheet to the door.  Mundinu sanded down all exterior teak panels and trimmings.  Then we applied 2 coats of West system epoxy to the panels and trimmings.  This job seals the wood once and for all, and is a sort of primer for the 2 part Varnish, Perfection Series by International Paints, which I intend on using for all outside teak.  Sand down and level off the bilge, under the engine, and covered this with West System Epoxy and filler.  We also plugged the hole where the fishfinder stem was, as this was a 2" hole and the new fishfinder has a 1" stem.  Will apply west system epoxy and west system sheets to the hole, sand down, fair to a smooth finish and apply the 6 coats of west system barrier to the outside part of the hull.
Continued to laminate the inside removable panels, which are now complete. Also managed to do some odd jobs which were pending, like removing and refitting the stainless steel railing (port side)...had to dothis job as at one point where the railing fixes to the cabin we had a water leak.  Removed all the teak wood from the inside cabin, this will be sanded and varnished with Perfection Series as well.

Last Thursday we also transported the Steyr engine to the mechanic to get the fuel injectors re calibrated. While the engine is there, it'll get a new timing belt, and the intercooler gets a cleaning. 

Next Saturday, we'll fix all laminate to the inside fixed panels,  this job should take us all day, as there is quite alot.  Once that job is done, in 2 weeks time I'll have the DC cable in hand and commence the DC wiring!!!
Title: Re: Winter Projects on The Gaffer
Post by: fava on January 11, 2010, 09:45:10 CET
Seems to be one hell of a perfect project in the end!
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on January 20, 2010, 10:40:30 CET
Project Update:

Last Saturday (16/01/10) continued with our Project on The Gaffer.  Woke up to a very windy/rainy day.  We continued to laminate all the inside panels, and we can safely say that all paneling is now complete.  We still have to trim all the extra laminate off the work we did on saturday.  It was rather a tough task as we couldn't work near the boat, the wind kept blowing away the laminate away so we had to use the garage as a workshop instead.  It was up and down the boat all day. Meanwhile, I also located 3 small water leaks.  2 were coming in from the bolts that tie down the cabin to the deck, the other one from the front cabin window packing.  As it was raining all day, we could not fix the leaks at that time.  However, these will be fixed this Saturday. 
Meanwhile, I recieved the much awaited shipment of cables here in the UK, so when I'm back this week, while Mundinu can continue to trim the laminate, I'll commence the DC wiring of the boat. 
Yepps, things are moving pretty quickly, with alot of coordination between Mundinu and myself.  The Gaffer should be finished fom all major works by April, until which time we still have to complete the cabin upholstery, prepare the hull for a paint job, and probably even change the cockpit window sliders!
Engine Update:
Steyr mechanic called me up and asked me to visit the workshop.  The Unit injectors were calibrated, however the mechanic stated that out of 6 units, 4 did not need calibration, and the other 2 were just slightly off, but within recommended maker's tollerance.  This means that the white smoke during engine idle was not caused by the Unit injectors being dirty or out of calibration.  However, when he proceeded to clean out the After Cooler, this was found to be clogged.  Also, the Turbo fins had a film of black oil on them too.  According to the mechanic, This is the real cause of white smoke during idle.   .  Engine timing belt has been replaced, and while the timing cover was off, mechanic noticed that the fresh water pump and the belt tensioner(which are driven by the timing belt) had a slight 'GGGrrrrrrrr' sound when turned, meaning thatthe ball bearing was acting up.  Mechanic recommended replacement.  So, we're waiting for shipment of the tensioner by DHL, as the local agent hadn't one in stock, as once fitted, we start the engine and bench test.

More updates to follow.......

Title: Re: Winter Projects on The Gaffer
Post by: Pauline Tuna on January 20, 2010, 10:51:51 CET
AAw siehbi........alungi alungi alungi alungi & alungi.....lol @ chronic alungaitis as same here - we should be admitted to a same new ward at Mater dei Hospital for observation loooool
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on February 01, 2010, 11:09:34 CET
Project Update:

Well, works are progressing at a satisfactory pace on the Gaffer.  We finished all the panel laminatation, and everything is now ready to be fixed in place.  The present console was cut out to accomodate the engine instruments, as these will be moved from their present position to accomodate the new GPS/FF electronic equipment.  
The original tranducer 2 inch hole was plugged using a proven method by west system, whereby the 2 inch hole was 1st plugged using west system epoxy  ( the hole is bevel filed on both sides to a 45 degree angle, plugged on one side, and WS epoxy poured into the hole at the other end, leave for at least 24hrs to set, fair down to level with the present bottom layers - this way the plug has nowhere to go as it is tightly secured by the 45 degree bevel angle........allow me to illustrate, >____<  ) and then layered with epoxy and WS fibre sheets on both sides, inside and outside,  according to manufacturer's specifications.  Then sanded and faired smooth with 200 and 400 grip sand paper.
The DC distribution box was also fixed in place, and on Saturday we started the long awaited DC wiring of the boat.  All wiring connections and connector butts are being crimped in shrink warp tubing butts to prevent mositure buildup or corrosion.  When the butts are fixed to the DC equipment, silicon is applied for further protection.  

As I said, progress is satisfactory, I have now all teak trimmings in the garage, sanded and smooth ready for two coats of Perfection 2 part varnish, the varnish will be finished off this week, and ready for next Saturday to enable Ray (Mundinu) to start fixing the teak in place while I continue the DC wiring.

Engine Update:  The mechanic called me up today with some interesting news.  Following an individual injector test, he found 3 out of the six injectors were dirty.  
Some injector theory.  Steyr use a 2 stage electro/mechanical fuel injection system. There is no diesel pump involved.  First stage controls fuel flow to combustion chambers prior to turbo engagement, and the second stage includes turbo engagement.  Seems that the problem lies with the 1st stage injection system.  3 out of 6 injectors are not perfroming to their optimum capacity, with the result that unburnt fuel is being expelled from the engine in the form of white smoke when engine is in idle position.  Smoke dissapears as soon as the engine speed is increased beyond the idle revs...(e.g. engine idle revs  @ 635rpm,  White smoke disappears at 650 rpm).  These injectors have been removed from the engine, and will be sent to Steyr motors in Austria for cleaning and calibration.   To simplify matters, all 6 injectors will be sent to Steyr for inspection, better have all injectors inspected, as most probably all will need internal calibration anyway!
For the mechanically inclined, I am attaching a pic of the 2 stage fuel injector.
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on February 15, 2010, 16:02:18 CET
Project Update:

Electrical Installation
AC/DC Wiring nearing completion now.  All DC wiring at the lower helm is finished, and all connections to DC equipment have been crimpped and tested.  Tomorrow will spend a day finishing off the DC wiring to the Flybridge.

Engine Update
Well, as I said in my previous update, the unit injectors have been despatched to Steyr in Austria for cleaning, servicing and stage calibration.  Still awaiting news from Austria ??? ???

Fuel System
Took apart the Racor filter and it was clogged :-[ :-[.  Just as a reminder, this same filter unit was dissasembled and reassembled only last August, so definitely the fuel tank is coming out and a thorough cleanup of the tank must be done.  Seems I didn't get rid of the gunk in the fuel tank last time I cleaned.  This time it will be different....I plan on steam cleaning the tank to get red of any fuel bugs that might be lurking in the corners...good wash down with either white spirit or thinner, and then a rince with clean diesel....that should do the trick...hopefully....(any more ideas welcome)
The Racor unit filter is also off for a service...to Guido99 for a complete refurbishment at his company.  Well, I noticed that the paint on the inner walls of the unit was peeling off, can't have that inside the filter, as it will compromise the filter carthridge with pieces of peeled paint.  So, get rid of the paint, cleaning and repainted with fuel resistant paint. 

Teak Varnishing

Last Saturday I applied the first coat of the 2 part epoxy based varnish to all interior and exterior teak...the shine is already there guys ;) ;), now weather permitting, I'll apply the second and final coat for that deep gloss only achieveable with 2 part varnish.

Well guys, things are looking good, and we should hit the target date to launch early May 2010!.  Still some work to do, especially on the interior, upholstery, fitting in some collapsable seating at the back, and hopefully The Gaffer will be sporting a new Stainless Steel Radar Arch as well.  Will keep you all updated.
Title: Re: Winter Projects on The Gaffer
Post by: twoutes on February 16, 2010, 03:40:11 CET
Looks like its coming along nicely.

looking forward of seeing some 'after shots' soon.
Title: Re: Winter Projects on The Gaffer
Post by: benri on February 16, 2010, 07:36:28 CET
keep it going The_Gaffer.... some pics when available or you can invite us all to have a look :-)
Title: Re: Winter Projects on The Gaffer
Post by: shanook on February 16, 2010, 10:03:16 CET
and a boat warming party would be nice as well, of course drinks and booze on the gaffer............
Title: Re: Winter Projects on The Gaffer
Post by: Destination Sea on February 16, 2010, 10:14:00 CET
w appitizers   bil goff  ;D 
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on February 17, 2010, 09:06:59 CET
HOOVER!!!
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on February 17, 2010, 09:24:14 CET
Project Update:

AC/DC Wiring:
Finished the wiring to the flybridge and DC tails to all switches.  All whats left now is to connect the DC board to the Batteries and power up for a test.  From the flybridge you can control the navigation lights, anchor light, search light and horn, while I'll have visuals from both bilge pumps.  Also up on the flybridge I have installed an extra set of trim tab controls.  I have a DC 12v supply for extra radio, GPS and panel lights.

Fuel System:
Went over to MIL Ltd, Guido99 metal-workshop setup.  They run a very professional service there, specialising in blasting, galvanising and recoating of metals for all kinds of applications.  The Racor unit will be stripped of all paint, cleaned and repainted with a 2 part epoxy paint which is highly resistant to humidity and moisture, including immersion in salt water!.  I've also decided to change all supply and return fuel pipes and use copper piping instead.  Tomorrow we'll have the fuel tank out and give it a general super cleaning.  Asked around and it seems the best method is to open all man holes, spray degreaser inside the tank, let it set in for about 30min, and then using a power wash, rinse the inside of the tank making sure all extracts and deposits are flushed away.  Repeat process, and then thoroughly dry the inside of the tank, and rinse again using clean diesel.  That should definitely do the trick.



Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on February 19, 2010, 08:45:34 CET
project Update:

DC Wiring:  
Open the Champagne, we have achieved closure on this important milestone.  The DC wiring and connections were completed yesterday.  The Gaffer now boasts new DC wiring, new Distribution panel, all terminations and wiring in marine grade tin coated terminals and heat shrink sealed for added protection.  All wiring is either in double insulated marine grade coatings, or pulled through flexible marine grade tubing.  Job well doen!!...Thanks Ray!!
Tomorrow will complete the AC 240v wiring to the electronic battery charger, the AC/DC transformer, Alarm system (yes, I'm fitting an alarm system too), Honda Genset and 240v socket outlets.  

Fuel Tank
Took out the fuel tank yesterday, sprayed it with degreaser, and power wash down rinse with water.  The few remaining sludge clinging to the welded plates was removed using thinner, and then power wash down rinse.  The inside of the tank now is sparkling clean.  Tank was re fitted inside the Gaffer, and while the tank was out, we took the opportunity of upgrading the foundation where the tank sits.  Another job closed!!

Teak varnish
Weather promises to be favourable tomorrow to complete the second and final 2 part varnish on the teak trimmings on the Gaffer.  This week with the relative humididy in the 90%, was not ideal to apply the second coat.  Tomorrow, with the wind turning to NW, should be ideal.  
(http://maltafishingforum.com/talk/index.php?action-gallery;sa=view;id=3864)
1KW Transducer
RLR have advised that the B260 through hull transducer has arrived at their outlet.  We'll fit that in tomorrow as well.  Seen pictures of this beast, its about 22 inches long, and 4.5inches wide including the high speed fairing block.  Read on some forums that it is possible to flush mount, but you'd have to glass in the ducer for that.  Anyway, Airmar provide a high speed fairing block, and reports suggest that you can still get clear readings travelling at 25knts!

Works in Progress Photos
Tomorrow we'll take some pictures of the works in progress on the Gaffer.  
Title: Re: Winter Projects on The Gaffer
Post by: benri on February 19, 2010, 09:06:07 CET
prosit joe... keep it up mate!
Title: Re: Winter Projects on The Gaffer
Post by: robby017 on February 19, 2010, 09:10:56 CET
well done Joe, keep up the good work.........
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on February 19, 2010, 09:37:49 CET
Anybody who cares to pay a visit to see the works in progress, is more then welcome to do so.  I'm at the Holma Boat storage facility in kalkara tomorrow from 8.30am till about 5.00pm
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on March 03, 2010, 10:10:40 CET
Project Update

Teak and Laminate

recieved the last sheet of laminate which we ordered from P&M and replaced all laminate sheets on kitchenette cupboard doors and compartment doors.  All fittings now have been taped with the laminate trimming and ready to be fixed in place.  Will fix them in place once we apply the final coating of the 2 part varnish, scheduled for tomorrow.

Varnish

As stated above, we are now only one final coat away from finishing the varnish.  Could not apply the final coat last Saturday as the boat next to me was having its hull sanded down, and the air was full of dust and particles.

Electronics

I recieved the new Raymarine C90 Widescreen last week as well.  We've already cut out the console to fit in the C90W and once all works in the cockpit are complete, we'll just fit it in, wire up and job complete.  The extra wireless autopilot module is also in hand, and I've hot wired everything in the garage just to make sure everything works well.  Will fit in this with the C90W.

Ceiling and Cabin Upholstery.

Yesterday we cut out the boards which will be fitted to the ceiling.  The boards took some time to fit in as they needed to be cut at various angles and lenghts.  We did manage to finish off the job though.  Now all whats left is to stapple on the upholstery to the boards, fit the boards to the ceiling and wire up the inside cabin lights ;) ;).   Once we have that sorted, we'll start covering the hull sides with upholstery.  Bought the upholstery yesterday from O'Flaherty, together with the necessary glue.  Ceiling will be in a cream colour padded PVC, while the sides will be in a beige light colour, which is about 3 shades darker then the ceiling.

Engine Update

last update 3 weeks ago was that the injectors were sent to Steyr in Austria.  Well, knowing my luck, as soon as Steyr were going to start the ultrasonic cleaning process (a process by which high ultrasonic sound waves are directed at the injectors which hit the carbon deposits on the nozzles and clean them)...the machine malfunctioned >:( >:( >:( >:( >:( :'( :'( :'(
That was last saturday, haven't had an update since then.

Project Deliverables against Planned Timelines

What can I say.  Progress is on track to achieve closure of the project as planned.  The delay in the engine does in no way effect the works being carried out.  Tomorrow we finish off the varnish, and some odd jobs like fitting in the new 240AC panels, fitting in the new bilge blowers and fitting in the new genset.  All electrical connections to these are in place.  Saturday we'll upholster the ceiling, and fit in all side panels which will support the ceiling.  Then, we'll start the inside cabin upholstery.  Once that is finished, we'll start the works on the outside hulls, alot of prep work involved to get the hull ready for the paint job.  meanwhile, we'll start work on:

The new S/S radar arch
Exchange the engine controls to new Morse controls
Change all fuel lines to copper piping
Repaint the engine gears
Fit in and align the engine into its bay
Modify the cockpit canopy to stop water from entering the bilges
Glass in the keel hull to prevent rain water from entering the bilges
Fit in a pair of retractable seats at the back to accomodate 2 persons each

And 101 other odd jobs which my mind does not stop reeling about.....


Title: Re: Winter Projects on The Gaffer
Post by: caldaland on March 03, 2010, 11:07:28 CET
your dedicated work sounds like bad news for the poor alungi! lol!
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on March 03, 2010, 14:08:12 CET
Engine Update

BAD BAD Bad news guys!!!.  just got off the phone with the mechanic...it seems that 4 injectors are not servicable.  The bad news gets even worse!!!!....Steyr have discontinued the injector model I sent in for servicing, and there is a newer model in service now.  So, bottom line is I have to replace all 6 injectors.  but it gets even worst....Not only must I change the injectors, I even have to replace the engine ECU, as this is programmed to be compatible with the original injectors, and has to be replaced to control the new ones!!!!So, my life savings...yes, it'll cost around 4000 Euros....are being invested in new injectors and engine ECU.  all donations are welcome:P
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on March 03, 2010, 15:50:40 CET
Further to my previous post, I got in touch with Steyr motors in Austria, and requested a detailed explaination of the situation with the injectors.  Unfortunately, being a high end manufacturing company, their core business is producing engines, and not repairing injectors.  The injectors are servicable, however, the cost base in Austria is too high and not feasible for them to be serviced there.  So, I asked again how much it would cost me for the new injectors?

Steyr, knowing the goodwill that exists between us, and the high exposure the engine receives on this forum and elsewhere, have been kind enough to grant a generous discount on the purchase of the new injectors, to which I finally agreed.  I am now looking at alot less than quoted in my previous post.  Still expensive, however, the Steyr engine will have new improved injectors, new ECU programming, and more efficient service ;D ;D

Guys, it pays to be a member of this forum, and is beneficial to have goodwill in place when one requires help from a leading manufacturer.  

more updates to follow......
Title: Re: Winter Projects on The Gaffer
Post by: caldaland on March 03, 2010, 22:37:34 CET
welldone!
Title: Re: Winter Projects on The Gaffer
Post by: Destination Sea on March 03, 2010, 23:02:38 CET
Joe check with  them if the ECU can be reprogrammed. Most ECU are now of the Eprom (erasable programmable read only memory)type which can be reprogrammed/ updated instead of "having the chip replaced". there are other versions such as EEPROM/Fprom Flash  erasable etc or electrically erasable etc.Just programming will cost less than a new one.
Title: Re: Winter Projects on The Gaffer
Post by: MartinB on March 03, 2010, 23:31:23 CET
Well done from me too! Obviously you expect a few hiccups when you take on such a mammoth project,but hopefully this will be the last 'major' hiccup you encounter mate :)!
You make a very valid point about the exposure companies receive too,as speaking from the 'lay' mans point of view,i would have never even realised that Steyr continued too make engines!!..Tbh previously the only way i would have associated them before you started the thread on this project,is through the Steyr Aug (assault rifle).
Title: Re: Winter Projects on The Gaffer
Post by: skip on March 04, 2010, 07:27:41 CET
Good point though Steyr make engines that were used in tanks like the Scorpion, Steyr Motors also have a brand new serial Hybrid Propulsion System for pleasure boats.

They were previously part of Steyr-Daimler-Puch, their military division http://www.steyr-ssf.com/ was sold to General Dynamics but the company we are referring to are Steyr Motors GmbH which in 2001 became an independant company producing Diesel engines :)
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on March 04, 2010, 15:06:55 CET
Correct guys.  Steyr still do a number of marine/land and air engines to serve the military around the world.  The MK 246 high power diesel engine (the one fitted on the Gaffer), is the engine on thew famous scorpion Tank.  There is a WAR BUTTON on the panel, that is activated, will give you 5600rpm instead of the rated 4200rpm, however, once activated, the Guarantee is void!
Also, Stery are the first company in the world to produce the Hybrid engine for marine pleasure use, which switches from piston driven (diesel) to electric. 
Title: Re: Winter Projects on The Gaffer
Post by: shanook on March 04, 2010, 15:09:42 CET
wow the gaffers new name THE TANK......... i kinda like it.......go for it Joe
Title: Re: Winter Projects on The Gaffer
Post by: robby017 on March 04, 2010, 15:52:52 CET
QuoteThere is a WAR BUTTON on the panel, that is activated, will give you 5600rpm instead of the rated 4200rpm

:o :o :o :o :o :o

cool......... that's a nice and handy gadget to have......  ::)
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on March 04, 2010, 19:54:44 CET

True Robby. However you risk running the engine at an extreme. The war button is used by tanks to get out of the way....fast
Title: Re: Winter Projects on The Gaffer
Post by: robby017 on March 04, 2010, 22:14:13 CET
of course, but if you've got someone seriously injured on board and need to get in fast from some 20-30 miles offshore........ i think you'd hit it there...... life before engine guarantee surely..... i wish you never use it though.
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on March 29, 2010, 12:24:40 CET
Project Update

Been a while now since my last update, but I can assure you that works have been progressing as planned on the boat, with all major projects successfully completed, and other in their final stages of completion.

Just a quick summary:

Teak and Laminate:  Completed  :)
Varnish:   Completed  :)
Cieling and Cabin Upholstery:   Completed  :)
Complete rewiring of all DC circuits:  Completed   :)


Electronics

All the electronic equipment ordered from RLR has been delivered, and everything is installed and connected.  All that remains to be fitted is the actual Raymarine C90 Widescreen.  As this is a sort of delicate product I'm leaving it to the last thing to be installed since there still remains some work to be done on the cockpit.  However, the inlaying of the panel is complete, and all whats left is just to fit the screen into its position and screw in.   :)

Engine
As I write, I'm still awaiting delivery of the 6 injectors.  Steyr wrote in to confirm dispatch and payment to Stery was effected.  The ECU was reprogrammed  and mapped to the new injectors, with a new fuel and speed optimisation included in the programming logic.   ???

Repainting the hulls/ Cut and polish of existing gelcoat
After much deliberation, and testing on small patches of the hull, a final decision has been taken.  The hull is recieving a once over cut and polish.  The gelcoat is being wet sanded with 600 grit sand paper to remove all the oxidised gelcoat and stains.  Then wet sanded again with 2000 grit sand paper to remove most of the scratches caused by the 600 grit sanding.  This sanding is being done by hand, with water and a little soap to reduce friction.  Next will be the application of G3 abrasive paste,  polish and buffering.  Followed by G10 paste polish and buffering, and finally apply waxing a teflon to reduce the effects of UV.  most of the starboard hull is complete, except the fianl wax polish, and the shine to the original gelcoat has been restored.   I must admit we have a professional doing this job, as its very time consuming and would distract us from the works that are left to complete this project :o  :)  ;)


Most of the other 101 odd jobs are either complete or nearing completion, with the 240V AC panel all wired up, the keel has been glassed in to prevent rain water seeping into it, and the new fibreglass panel to accomodate the engine instrument panel all glassed and ready to fit.   :) :)

Last saturday we also started work on fitting in the new Stainless Steel Radar Arch.  This is all new work for me, as I am a keen welder but never welded using the latest tig technology and SS.  A friend of mine gladly lent me his equipment, and we'll see how that progresses.  Resited to the arch will be both VHF antennas, the anchor light, new TV arial, and space for the Radar (maybe next year)

Well, thats the latest till now. We should be ready 1st week of May, and then the Gaffer gets launched for the season, starting off with some deep fishing trips and while out there, start marking off some interesting drop offs!!!
Title: Re: Winter Projects on The Gaffer
Post by: Granitu on March 29, 2010, 12:38:32 CET
beautiful posta s always gaffer

just a little suggestion.
why don't you send a sample of the maltese available diesel gaffer...or analyze it in mlata and send them the results to see what they recommend. just a suggestion since we have a very low quality diesel which may well be damaging your injectors gaffer... and injectors do cost some money...

i'm telling you this because in past we had issues with injectors because of poor diesel on our buses engines... it may well be a low quality refining process that causes all this.

that could put your mind at rest once and for all
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on March 29, 2010, 12:43:33 CET
Thanks for the valuable info Granitu.  sadly, we do seem to have a very low quality diesel in Malta.  I've been told to install additional filtering, as Steyr (like any other modern common rail diesel) recommend 2 microns of filtering before the diesel enters the injectors.  Some people recommended that I use additives whenever refueling, thus pushing up the octane rate of the diesel.  What are your suggestions please?
Title: Re: Winter Projects on The Gaffer
Post by: Granitu on March 29, 2010, 13:46:19 CET
i would go for filtering gaffer.

with mixing you would need it evenly balanced. just adding additives which may have a different liquid densities than diesel is risky and in such instance it is a laborious process to mix it.

if the two have different densities gaffer you would end up with 2 levels, one of diesel and another of the additives in the fuel tank, something not very recommendable... to try this point out, try pouring some oil in a glass and then water, and you will be amazed.. there are 2 different levels of liquids

so if using additives, do this simple check first and if they have similar densities, well that might be possible to do.

you may buy in large bulk, filter it and store it. it may well save you some possible hassles that can arise.
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on April 06, 2010, 15:22:08 CET
Project Update

Spent last Saturday and monday finishing off minor works (irqaqat) on the Gaffer.  I'm always surprised at the amount of small jobs that seem to accumulate and you spend hours on end trying to finish.  

Engine
I have just been informed by Steyr Motors that the new injectors and re programmed ECU are in transit to Malta as they were dispatched this morning.  Thank you Steyr!!

Radar Arch
A very good friend of mine gave me his stainless steel radar arch.  I'm trying to fit it onto the flybridge of the Gaffer.  Since the boat werethe radar arch was installed was a 40 footer, it's a bit wide for my boat.  So we cut the SS pipes in the middle, and reshaped it to fit the Gaffer.  All I need now is to weld the pipes together again and polish off the welding.  I got a quote from a guy yesterday, he asked me...yeah...wait for it.....ara gejja....390Eur + VAT just to weld and polish >:( >:(....it was one of those rare moments where my mouth literally dropped....390E for welding 2" pipes toegther and polishing...thats daylight robbery.  Opened a thread this morning asking for some advice, and got quite a few I must say.  Will contact them tomorrow and see who (a) gives me the best quote and (b) can finish the work in the least time possible.  I'm not saying I want the job done for nothing, but geez, I calculated there is about 60 to 90 minutes worth of work there.  390E + VAT for 90minutes, heck, I'm in the wrong job mate here!!

Still have to paint the new engine instrument console and side cockpit panels, however already bought the paint and will do this during the week.  

Flybridge Helm
Didn't use the flybridge last year as I ahd this embarassing hydrolic leak which I could not for the love of God stop.  I finally decided to take the whole helm apart and investigate further.  What I found was shocking.  When I had the flybridge helm installed, I was working abroad, and got some installers to fit in the new helm.   Instead of the recommended hydrolic washers, these installers used Teflon tape ??? ???
So I dismantled the helm, brought it back to the garage, bought new hydrolic washers and stuff, and reassembled from scratch.  No leaks now ;) ;)

Pictures.
I'm awaiting the new pics to be emailed to me, once done, I;ll puit them up on the forum.
Title: Re: Winter Projects on The Gaffer
Post by: benri on April 06, 2010, 17:19:58 CET
Go on Joe - nice progress! Apparently you'll soon be done! and believe me there's no more satisfaction than doing the job yourself. Keep us updated! If you don't manage with the guys the other members have recommended for the s/s, just drop me a message and I can take you to a guy in the l/o Zabbar.
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on April 08, 2010, 08:58:41 CET
Project Update

Engine
The injectors and ECU are here and being assembled by the mechanic. 
Title: Re: Winter Projects on The Gaffer
Post by: Destination Sea on April 08, 2010, 20:20:59 CET
If i recall correctly you have unit injectors. Well basically they programm the ECU in order to analyses all of the relevant status parameters in the system relative to engine and its operating condition and defines the exact start of injection and injected fuel quantity for the operating state of the engine at any given time. Thus optimizing  fuel economy and performance. Well with regards to cetane improvers (octane for SI engines) they are added to promote good ingnition response. i.e they improve the fuels combustions properties.However  I doubt i they have a lubrication effect on the system. As granitu said they may not mix completly- so check it out first.Most of them are alcohol derived esters of azotic acid.I heard of two instances about 3 years ago  where one type of additives  was added but did not mix throughly. Thus when drawn through the pump it "evaporated with the heat" and the pump lost its tolerance- there was no lubrification effect. I think good filtration is the way forward.I am glad that they have reprogrammed the ECU as stated before nowadys they can be reprogrammed/updated.At least some costs saved. Good luck  and god bless.
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on April 09, 2010, 09:03:15 CET
Thanks for a very informative and comprehensive explaination of additives and fuel mixture.  I have been in contact with Steyr motors and their recommendation is to filter the fuel through a 10 micron water separator filter (like the Racor 500 series) then through the Steyr original engine filter.

I have also gone one step beyond that.  I just bought a Racor fuel funnel filter which filters the fuel at 85 microns, thus capturing water droplets present in the fuel and any contaminants before the fuel enters the fuel tank.  I just hope this is a satisfactory measure. 
Title: Re: Winter Projects on The Gaffer
Post by: shanook on April 09, 2010, 09:19:04 CET
I would go a step further and buy good diesel..........
Title: Re: Winter Projects on The Gaffer
Post by: skip on April 09, 2010, 09:21:31 CET
From where?!!!
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on April 09, 2010, 09:31:07 CET
Quote from: shanook on April 09, 2010, 09:19:04 CET
I would go a step further and buy good diesel..........

Tony, believe me, I have always sourced 'good diesel'.  I either buy direct from a filling station, or use the Bulk service provided by 'Falzon Service Station'.  If you have a better source, please tell me.
Title: Re: Winter Projects on The Gaffer
Post by: bigboy on April 09, 2010, 09:42:11 CET
Try island bunker Oils. Never had any problems
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on April 09, 2010, 09:46:44 CET
Quote from: bigboy on April 09, 2010, 09:42:11 CET
Try island bunker Oils. Never had any problems

Who are they Bigboy, do you have contact numbers?...will they come to msida Pontoons?
Title: Re: Winter Projects on The Gaffer
Post by: camkev on April 09, 2010, 09:58:57 CET
Island Bunker Oil Ltd.    10A Il-Moll tal-Hatab Marsa 21225526
 

21312490
23451000
21316244
21316243
21317433
'Warehouse', Triq tal-Lampat, Gudja  21225531
21806384
   
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on April 09, 2010, 10:13:05 CET
Quote from: camkev on April 09, 2010, 09:58:57 CET
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. 
Title: Re: Winter Projects on The Gaffer
Post by: bigboy on April 09, 2010, 21:42:42 CET
Quote from: The_Gaffer on April 09, 2010, 09:46:44 CET
Quote from: bigboy on April 09, 2010, 09:42:11 CET
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
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on April 12, 2010, 13:10:26 CET
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!
Title: Re: Winter Projects on The Gaffer
Post by: alfadelta on April 13, 2010, 20:04:28 CET
Prosit Joe, looks like everything is under control! ejja ha imorru ghal alungi
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on April 14, 2010, 05:45:30 CET
Yes Antoine.  We're at the final stages of completion now, boat should be ready on schedule for launching in May.
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on April 16, 2010, 08:21:42 CET
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 ;)
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on April 26, 2010, 08:40:57 CET
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 (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.
Title: Re: Winter Projects on The Gaffer
Post by: alfadelta on April 26, 2010, 19:34:19 CET
Prosit Joe, The Gaffer seems to be on track for the 'Oris Alungi Competition'
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on April 28, 2010, 08:31:13 CET
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. 
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on May 12, 2010, 08:21:08 CET
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!
Title: Re: Winter Projects on The Gaffer
Post by: bigboy on May 12, 2010, 08:58:38 CET
Welldone great project !
Title: Re: Winter Projects on The Gaffer
Post by: malvizzu on May 12, 2010, 09:24:00 CET
Good luck for the new season!!
Title: Re: Winter Projects on The Gaffer
Post by: caldaland on May 12, 2010, 10:16:13 CET
i already feel sorry for the fish gaffer! lol
Title: Re: Winter Projects on The Gaffer
Post by: skip on May 12, 2010, 13:26:29 CET
Certainly an awesome achievement, so far this topic has been read 3110 times, a testament to the level of interest it has generated on the forum and the sheer size and scope of this project!!

I'm not sure if Joe and Ray kept track but it would be interesting to know the number of hours spent over the past few months.......

Would love to have come down to photograph the launch unfortunately I'm stuck with having to work this Saturday - Good Luck and Keep us posted on how things go.
Title: Re: Winter Projects on The Gaffer
Post by: Shaftbomb on May 12, 2010, 14:08:19 CET
Prosit Gaffer - I myself learned a lot from this topic!
Title: Re: Winter Projects on The Gaffer
Post by: redbus9 on May 12, 2010, 17:21:55 CET
C
Congratulations on finishing your boat, and thank you for keeping us updated on the project, very enjoyable reading about it.
  ;D   ;D
Title: Re: Winter Projects on The Gaffer
Post by: kris on May 13, 2010, 15:57:39 CET
Well done joe!! :D
Title: Re: Winter Projects on The Gaffer
Post by: rammx on May 14, 2010, 05:45:27 CET
Proset Gaffer & Mundinu for all the work you did...Wish you all the best & double the fish you immagine to catch :)
Title: Re: Winter Projects on The Gaffer
Post by: benri on May 14, 2010, 06:06:03 CET
great job Gaffer & Mundinu.... Prosit! And there's nothing better than the jobs yo do yourself!
Title: Re: Winter Projects on The Gaffer
Post by: kris on May 14, 2010, 14:02:52 CET
prosit mundinu aswell as i forgot to tell u my friend ;)
Title: Re: Winter Projects on The Gaffer
Post by: shanook on May 14, 2010, 14:04:32 CET
well spoken bryan............u have first hand experience in that eh...
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on May 15, 2010, 16:43:20 CET
Project Closure

The Gaffer was launched today at exactly 10.30am from Kalkara Creek.  As there was a huge swell, I hastened the departure and mae my way towards the opening of grand harbour.  1st thing noticable was the engine decibles have gone down by about 10db.  This is attributable to the fact that we increased the sound proofing inside the engine room to cover all the engine surroundings including the forward and aft bulkead.  This surely paid off.

Second thing I noticed was the way the engine accelerated.  The response time is now much quicker, and at 2500rpm The Gaffer was up on plane!!.

Outside Grand Harbour, the wind was blowing a good force 7 and gusting even more...the Gaffer showed her true sea worthiness as I drove her straight into the wind doing 16knts.  Then at tigne point I turned and headed into M'xett harbour towards Msida Marina.

This is where it got exciting.  The wind had picked up a bit by then, and was surely gusting strongly, as I approached the pontoon, I faced a NW'ly headwind, and each time I turned the bows to berth the Gaffer, she would drift off course away from my slot.  So, to cut a long story short, I turned the gaffer around and headed bows first into the pontoon.  we faced a sho0rt period of agony while I held onto the gaffer for all my life, as the wind kept pushing the stern away from the pontoon berth.  In the end, a few good hearted souls offered thir help and we managed to berth the Gaffer inside her berthing slot. 

Well, thats the end of it, or the beginning of a new season for the Gaffer. 
Robby17, Guido99 and Venere, prepare yourselves for a retake on that alungi trip.
Title: Re: Winter Projects on The Gaffer
Post by: twoutes on May 16, 2010, 05:12:27 CET
Looks like all your hard work paid off. I look forward of seeing some photos of the new 'Gaffer'. don't you just love the wind  :-\
Title: Re: Winter Projects on The Gaffer
Post by: skip on May 16, 2010, 17:03:42 CET
I'm sure Joe was saying 'Bow Thruster', 'Bow Thruster', 'Bow Thruster' !!!
Title: Re: Winter Projects on The Gaffer
Post by: robby017 on May 16, 2010, 22:29:40 CET
QuoteWell, thats the end of it, or the beginning of a new season for the Gaffer. 
Robby17, Guido99 and Venere, prepare yourselves for a retake on that alungi trip.

thanks & good job, force 7 is no joke....... ps, you forgot clayton ;)
Title: Re: Winter Projects on The Gaffer
Post by: The_Gaffer on May 17, 2010, 09:18:11 CET
Quote from: robby017 on May 16, 2010, 22:29:40 CET
QuoteWell, thats the end of it, or the beginning of a new season for the Gaffer. 
Robby17, Guido99 and Venere, prepare yourselves for a retake on that alungi trip.

thanks & good job, force 7 is no joke....... ps, you forgot clayton ;)

And Clayton....forgot about him ostra!!!
Title: Re: Winter Projects on The Gaffer
Post by: MartinB on May 18, 2010, 04:39:34 CET
Many congrats on finishing your project! (or mission more like it :) ) was a very informative read! Best of luck in the upcoming season!