Engine Air Filter

Engine Air Filter

Nov 8, 2017

  • Action: To Do List item A0246 - Obtain engine air filter and install.
  • Completed:  8 November 2017
  • Cost: $37.99

While reviewing pictures of the engine, the following picture of the Yanmar 4JH5E air intake manifold caught my attention. Something just did not look right.

    I checked the Yanmar parts diagrams, pictured below, and it matched what Yanmar specified.  This engine has no air filter element, just an intake hose (15) and plastic suction manifold (14).  This means any particulates, dust, hair, or debris can make it's way into the engine - not a well thought out design.  This installation could easily be improved upon to protect the engine.

      Researched the internet and found a potential air filter candidate: a K&N RC-0870 High Performance Universal Clamp-on Chrome Air Filter.  It's height  was short enough to fit the confined area on the engine and the diameter of the hose tail would fit the inlet of the suction manifold.  Found the lowest price on Amazon.com and ordered it for $37.99.

        The K&N air filter fit on the suction manifold perfectly.

          Installed the suction manifold with the K&N air filter back on the engine - perfect fit and clearance!

            Added to the To Do List:

            • A0246 - Obtain engine air filter and install.

             

            Propeller Install and Paint

            Propeller Install and Paint

            Oct 24, 2017

            • Action: To Do List item A0064 - Sand the propeller and apply protective prop paint.
            • Completed:  24 October 2017
            • Cost: $129.99

             

            After the propeller shaft was installed, it was time to install the propeller.  The propeller shaft seat area had a thin layer of Lanocote applied for corrosion prevention.  The shaft key was installed in the slot and the propeller slid on. A rubber mallet was then used to firmly seat the propeller on the shaft.  The new bronze nut was installed and tightened, it had to be slightly backed off to align the cotter pin key way hole.  The cotter pin was inserted and then it's tangs were trimmed shorter to fit in the retaining slot when bent over.  The new size D prop zinc anode was installed.  Then the propeller was sanded again with 80 grit sand paper in preparation of primer paint application.  The reddish spots on the propeller are due to de-zincification - this is a result of not having a protective zinc anode installed on the propeller by the previous owner.

            We selected a Velox Plus Propeller Paint kit ($129.99) to paint the propeller with.

            The green metal primer paint was applied and allowed to cure.

            Next, six layers of the white propeller antifoul paint was applied. The primer and antifoul paint cans were sealed shut and retained for future use as approximately 75% of the paint still remained.

            Replacement 12 VDC Circuit Breakers

            Replacement 12 VDC Circuit Breakers

            Oct 22, 2017

            • Action: To Do List item A0178 - Obtain replacement 12 VDC circuit breakers.
            • Completed:   22 October 2017
            • Cost: $106.83

             

            New circuit breakers were needed to replace broken circuit breaker switches discovered during initial inspection.

            Researched the internet and located a installation manual for the BEP Marine Model 905DV DC Circuit Breaker panel that was installed aboard.  The manual specified that Airpax IEG and IUL magnetic circuit breakers are used in BEP Marine DC Circuit Breaker panels.  Located a Airpax manual that provided detail information and diagrams of their circuit breaker design.  This was compared to circuit breakers available from Blue Sea Systems, and was able to determined that Blue Sea Systems circuit breakers would fit the BEP Marine DC Circuit Breaker panel.  The notable difference was the terminal ring size on BEP Marine/Airpax DC circuit breaker was a #8mm, while the Blue Sea Systems circuit breakers terminal ring size was a #10mm.  Order and received the following replacement Blue Sea Systems circuit breakers.

             

            P/N Item Q Each Total
            7220 Single Pole Magnetic AC/DC Circuit Breaker 30A Black 1 $19.61 $19.61
            7216 Single Pole Magnetic AC/DC Circuit Breaker 25A Black 1 $19.61 $19.61
            7208 AC/DC A-Series Single Pole Circuit Breaker, 15 Amp, Black 2 $16.39 $32.78
            7204 AC/DC A-Series Single Pole Circuit Breaker, 10 Amp, Black 1 $16.39 $16.39
            7200 AC/DC A-Series Single Pole Circuit Breaker, 5 Amp, Black 1 $16.39 $16.39
            8035 Blue Sea Systems, Circuit Breaker Mounting Screws, Fits A Series and C Series 1 $2.05 $2.05
            $106.83

             

            In order to change the broken circuit breakers, the BEP Marine Model 905DV DC Circuit Breaker panel needed to be removed from it's installed location below the chart table desk.  Upon removing the panel mount screws, discovered there was not enough slack in the wiring to pull the panel forward to change the broken circuit breakers.  This meant the wiring would need to be removed from the panel - this was equivalent to opening Pandora's box, due to the rat's nest maze of wiring and the discrepancies discovered.

            Starting at the top of the DC panel each wire was removed one-by-one.  Numerous wire crimps to ring terminals were found with most of the wire strands broken off, it was just a matter of time before they completely broke off.  The majority of the wire terminals and the wires were not marine rated and would need to be replaced.  Numerous wires were discovered not connected to anything.  Numerous wire to terminal connections had excess insulation stripped away resulting in exposed wires with the potential for shorting out.  The excess use of butt splices to connect wires was absurd.  Probably the most telling example was a wire tee connection - the insulation was stripped away from the wire; wires twisted together; a touch of solder applied to hold the connection; and no insulation was applied to protect the connection.

            With the wiring remove from the DC panel, the circuit breakers were easily replaced.  The wiring discrepancies discovered are already encompassed with To Do List item A0185 - Redesign complete 12 VDC system installation.  To still have DC power for fans and lighting, make-shift wire jumpers were connected to the one 12-volt battery still aboard.

            PACO Power Inverter

            PACO Power Inverter

            Oct 21, 2017

            • Action: To Do List item A0177 - Delete PACO power inverter and associated wiring.
            • Completed:   21 October 2017
            • Cost: $0.0

             

            The two cables routed directly from the house battery bank to the PACO power inverter, without in-line fuse protection, were disconnected and removed.  The PACO power inverter was easily removed from the cabinet underneath the chart table.  Lastly, the 230 VAC extension cord with panel outlets and switches, that was mounted in the Nav panel at the chart table, was also removed.  At the same time, the 230 VAC powered Cannon printer, also located in the cabinet underneath the chart table, was also removed. All items were voluntarily taken away by Filipino yard workers.

            Rudder Gudgeon Mounts

            Rudder Gudgeon Mounts

            Oct 19, 2017

            • Action: To Do List item A0107 - Make and install rudder upper and middle gudgeons stainless steel backing plates and reseal mount bolt holes.
            • Completed:  19 October 2017
            • Cost: $12.50

             

            While re-sanding the upper rudder gudgeon mount, noticed that what remained of one of the mount bolt heads had a rusted powdery appearance.  We had previously noticed on the inside of the hull, the rust stain marks flowing down the hull from this location, resulting in this To Do List item.  Was surprised when we put a wrench on the inside nut for this bolt, and the nut just popped off.  We removed the two other mount bolts for the upper rudder gudgeon, and discovered this rusted bolt had almost all it's threaded length dissolved away. 

              The other bolts had significant signs of corrosion.  Lacking stainless steel plate material to make robust backing plates (this is a new To Do List item), we made a replacement out of wood and coated it with epoxy.  New 3/8"-16 x 3-1/2" Grade 316 Stainless Steel Hex Cap Screw bolts, washers, and nuts ($12.50) were installed with 3M 4200 Marine Adhesive and torqued tight.  The middle gudgeon bolts only required new sealant.

              These rusted bolts had the potential to adversely impact rudder mount integrity and emphasize that if rust signs are observed, don't delay, inspect and rectify - what should be a common sense response.

                  Added to the To Do List:

                  • B0223 - Obtain stainless steel plate material to make rudder gudgeon mount backing plates.

                   

                  Primary Zinc Anode

                  Primary Zinc Anode

                  Oct 18, 2017

                  • Action: To Do List item A0066 - Determine method to mount primary zinc allowing replacement without rudder removal.
                  • Action: To Do List item A0067 - Replace existing primary zinc.
                  • Action: To Do List item A0068 - Add bonding wires/terminals to mount bolts of primary zinc.
                  • Completed:   18 October 2017
                  • Cost: $86.26

                   

                  The bolt and nut arrangement was reversed from the original zinc installation, which would allow the primary zinc to be replaced without the need to remove the rudder.  Two ZHC-2 zinc anodes ($32.56) were ordered and received.

                  As the pictures below depict:  Wire ring terminals were attached to 10 AWG, green, marine rated, tinned wire ($40.00) and installed under two 3/8"-16 x 3-1/2" grade 316 stainless steel hex cap screws and on top of 1-inch diameter washers.  On the exterior side, 1.5 inch fender washers with nylon lock stainless steel nuts were installed securing the bolt installation to the hull.  The bolts were sealed with 3M 4200 adhesive sealant.  Excess sealant was trimmed clean.  The new zinc anode was installed with 1-inch washers and nylon lock stainless steel nuts.  The 10 AWG green wires were routed and connected to both boomkin stay internal mount bracket bolts.  The wood floor piece in aft-most bottom of the lazarette was rotted through and broke apart during the routing of the wires - it would need to be replaced. The cost of the hardware was $13.70.

                  Added to the To Do List:

                  • A0226 - Replace wood floor piece in aft lazarette.