Category: repairs

V-Berth Insulation, Part 2, Headliner Removal and Surface Prep

Brian finished the headliner removal this week. First, we unfastened a couple of stanchions, handrail bolts, and trim that were in the way. Next, Brian used a chisel, a multi-max, and some muscle to pull out the remaining sections of the headliner. Some pieces were tabbed to bulkheads with narrow fiberglass tape. These were more difficult to remove, but he got the job done quickly.  

Stanchion removal
The culprit! This rusty screw is evidence that water could intrude at the forward port stanchion base. We’ve been wondering how water was coming inside when we beat and bash against the elements. Now we know!
Overhead resin blobs
Headliner outside
Where air could access the edges of the headliner underside, mold took hold

The next step was surface preparation. The resin used to adhere the headliner was applied in large blobs. These blobs are now brittle and sharp around the edges. They stand out in green because the weave of the headliner remained attached to them. Removing the headliner unearthed a variable surface; resin in peaks and valleys, bare spots where the deck core almost peeks through. 

Leveling this surface completely is difficult and unnecessary. But Brian has used the variable speed angle grinder to smooth over the area. We are left with a more undulating and friendly surface to work with. In the coming weeks, we will attach a support framework or webbing to this imperfect, but improved surface. The webbing will support the deck from below. It will also create a network or grid of material that stands out from the overhead. Insulation will go in between the grid, and cover panels will mount to the grid.

Brian grinds the overhead

The refit is moving along now. We have taken steps to make things easier: our tools are ready to go, our workspace is clear, and we have what we need to move forward with our immediate jobs. It took a day to clean and organize our tools. Our Grandpa tools needed some tender loving care. All the tools are fairly young, but due to conditions in some of the storage lockers aboard, they have aged rapidly. The rented apartment has come in handy. We have pushed in as much as we can reasonably fit. Sails are stacked on bins. Buckets are stacked on boxes. Now that everything is off the boat, we have trouble remembering how all this stuff fit aboard little Dawn Treader. Added to the pile are some materials we had sent to Lukeville, AZ. With these, we now have all the items we need for our epoxy and fiberglass kit. We also made a trip to the big box hardware stores in the United States, and spent a few hours navigating the aisles.  

The jigsaw needed some rehab. Brian tapped in a new screw to hold on the guide plate.
Tool cleaning station
The epoxy and fiberglass kit is stocked!
Our big pile of stuff is still growing. And a sticky note version the to do list took over the refrigerator.
Estimating plywood needs

There are still big things missing from our supplies. We wish it were easier to find insulation and plywood, and we’ll need these and other things sooner rather than later. But, for now, at least we can keep going…

V-Berth Insulation, Part 1, Dismantle and Refit Plan

We spent the first few weeks of this refit period adjusting to life on land. We made trips away from the boat to see family. We gathered tools. We moved ourselves and everything off the boat. In week five, we took real action at Dawn Treader, and the boat was changed in a day.

Dawn Treader in the Boatyard

The V-Berth was dismantled. The side panels, insulation, port lights, and headliner were removed. The headliner was cut out with a multi-max. Roughly 70 percent of the liner now sits against the fence behind the boat. We were pleased that so much was removed so quickly. The liner was largely unattached to the deck above. We will remove the remaining sections of liner when we remove the thru-bolted handrails and stanchions on deck.

We found thin stripes of mold on the insulation when we removed the sealing strips of plywood on the sides of the V-Berth. We found mold behind the insulation when we removed the plastic panels and insulation above the shelves. We found mold on the backside of the headliner, around the border, the outside inch, when we cut out the liner in sections. Wherever air was able to flow a little bit, there was a little bit of mold. 

Stripes of mold where air had access.
In progress. Taking things apart from left to right.
We removed the insulation (that we installed in 2015)
Pulling plywood sealing strips.
Pulling plywood sealing strips.
Removing port lights

All of what we’re removing on the sides of the V-Berth, the insulation, panels, and sealing strips, we installed in 2015. This installation proved inadequate during three years sailing in colder climates. We made mistakes. We did not go far enough. We did not reimagine the V-Berth well for cold climates. As a result, we used this valuable living space for storage instead of sleeping. The mold in difficult to clean spaces was an issue, another was condensation. The original, uninsulated headliner created a large surface for condensation. Occasionally, we had rain inside. Big fat drops formed on the coachroof. We also had condensation problems on the overhead hatch, the hardware that held the side panels up, and on the metal port light frames.

Multimax cuts
First headliner panel cut out.
Headliner removal.
Remaining headliner. Stanchion thru bolts.
The headliner panels went overboard.

Many sailors fight condensation and mold. We hope our time in the desert, drying out and refitting Dawn Treader, will better prepare us for these struggles. We have learned many lessons in the past few years, and now we are re ready to try again. Our efforts will be more complex and lengthy this time. Our plans include adding an insulation supporting framework under the deck, and more of everything: insulation, heat, ventilation, air circulation, and access (we plan to widen the opening to the V-Berth). We plan to install different port lights. We will also replace the V-Berth platform again. The plywood delaminated in the rainforest. Our primary goal is to make the V-Berth inhabitable in all climates. Let’s see how it goes…

Integral Water Tank: Summary and Repair

We repaired our integral water tank a few months ago, here in Uruguay. This video is a recap of the build project from two years ago, and details of the recent repair. Overall, the integral water tank has been a vast improvement. It is easy to clean and fill. We are happy to make use of the space below our cabin sole that was filled with foam. The 65 gallon water tank makes long term cruising much easier.

 

Integral Water Tank Part 2

200 hours later, we finished the water tank! Parts 1 (Building an Integral Water Tank) and 2 combined for a rewarding job; now we have double the water capacity (65 gallons), more storage, and an easy to clean cabin sole.

Installing 3 inspection ports
Using an angle grinder to recess the inspection port to stand less proud
Dry fit
Brew coat on the bottom of the sole/tank top
Brew coat (second coat)
Third and last coat

After finishing the brew coat (a food grade epoxy coating), we prepared to epoxy the forward sole section and the main cabin sole/tank top into position. We applied epoxy to the tops of the flange from the old cabin sole, and to the new floors and baffles in the water tank.

Forward sole, to be glued down first
Forward sole section (future storage) with epoxy
Sole/tank top glued in! Filler pieces showing
FIlling/fairing compound
Fairing/sealing tank top in
Aft plumbing for vent and supply
Bilge side plumbing: vent and supply
FInished border paint (interlux epoxy primekote), also cream color interlux perfection with non skid
Yes!

We finished the project by filling and painting the border of our new sole. Our water system works great! Check out our galley post to see our bucket sink, foot pump, and water filter.

Repairing Compression Post Base

As we went further into project rabbit hole with the water tank, we found our compression post to be corroded. Dawn Treader’s mast is well supported by a two inch bulkhead, the compression post is fiberglassed to this bulkhead. This made us question the importance of the post, but we decided to repair it regardless. At this point, why not?

Building an Integral Water Tank

Our original project plans did not address changing our water tank. But, upon removing the engine, we gained better access and visibility to the water tank area, this revealed the need for further investigation…

Our work continued, and we ended up removing everything from the bilge: water tank, resin blocks, foam (so much foam). We discovered lots of usable storage after removing oily residue, cleaning, and drying out the bilge.

Removing the water tank revealed the need for reinforcing the compression post, read more in our related post (Repairing Compression Post Base).

Next, we need to construct a new tank! Our new tank will have an expanded footprint that extends well forward of the previous tank. Also, a new integral tank is a good choice for maximizing our water storage capacity. We hope to double the capacity of the previous tank (from 30 gallons).

This unexpected project has lots of benefits! We will be able to carry lots more water for long voyages, our hull has been reinforced with 6 new floors and a heavy fiberglass layup, and we now know Dawn Treader is clean from top to bottom! No more hidden treasures!

In part two we complete the tank with paint, install the tank top/sole, add plumbing and inspection ports.