Making roof panels for sailboat

After we have finished with the mahogany strips we started making roof panels so that the roof would match our beautiful new mahogany.

We bought a fake lather boat interior material at the boat store. We choose to buy the thinest version of the material, which was 1.2 mm thick. The reason for not choosing a thicker version was that the surface we want to attach them onto will be pretty smooth and then there is no need to have a thicker, more forgiving material.

preparing for roof panels on sailboat
First we have glued up pieces of wood onto the roof, which we will attach the roof panels onto.
Next step is to fit the plywood and cut it in the rights shape. We have used plywood that is WBP treated (weather and boil proof). We used 7 mm thick plywood so that the roof panels will be firm, if using thinner plywood it could start loosing it’s shape and start hanging and that we didn’t want. This thickness we choose feels very stable right now and hopefully it will stay that way.
Then we made an edge and fixed it with glue onto the plywood. And spend some time sanding it to have a smooth edge.
Next up is to glue the fake leather fabric onto the plywood.
This is the glue we have used. It is used for gluing bathroom carpets so very good for humid areas.
boat interior material onto our roof panels for the sailboat
Attaching the fake leather onto the plywood and making sure that there is no irregularities that will show later.
Finally we attached the edges with staples.
spotlights roof panel sailboat
We have also bought some spotlights we added onto the roof panels. Nice to be able to light the boat up 🙂
roof panels for sailboat
Some roof panels waiting to be set up in the sailboat! 🙂

Now we will just have to set up all the roof panels in the sailboat and after we are finished with that we are pretty much done with the interior (except some final fixes around the freezer and our fixes for the wood that was damage by a leakage). At least we want focus so much more on that right now before our departure but there are still a lot of things we want to improve but that will have to wait until the future.

We have also recently worked with repairing the damage done by the wood that was rotted, working with the freezer. More about that soon 🙂

Freezer progress

Lately we have continued with our future fish freezer. We have started to add insulation to it, in the form of some kind of styrofoam with closed cells. The closed cells means that it wont absorb any water.

Before we started adding insulation we replaced one of the “walls” to the freezer. The old one was pretty worn out and also had a big hole in it for the old chiller.

We replaced the old “wall” of the freezer box to a new fresh piece of wood instead.
First layer of styrofoam glued on the the sides of the freezer.

As mentioned above, the styrofoam we have used is a closed cell styrofoam. Each piece is 5 cm (2″) thick and for the side walls we will have 2 layers of styrofoam as insulation, so 10 cm (4″) in total. The bottom of the freezer follows the shape of the hull, which means it is not so easy to make pieces of styrofoam that fits. We also want to have a straight bottom, to be able to attach the aluminium we plan to have as surface in the freezer.

What we did to solve this was to make to “half-moon” (kind of) shaped pieces of styrofoam. The pieces follows the hull in the bottom and are straight on the top. We attached them on the hull next to the side walls. Then we filled the bottom of the freezer with expanding sealing foam between the half-moon pieces and attached a piece of styrofoam on top of that.

The bottom piece in position, underneath it we have filled up with expanding sealing foam.
After the sealing foam had dried, we drilled holes in the bottom piece and filled up with some extra expanding sealing foam to make sure the entire space beneath gets filled.

Next up will be next layer of styrofoam, prepare the aluminum pieces, fix the top part of the freezer and then add the chiller.

As we mentioned some weeks ago we also found some really wet wood when removing old insulation. We have started to remove all of this wet wood and today we actually found the source to the leakage, or at least one of them, there could of course be more of them. It is a hole  in the plastic in one of our open storages in the cockpit, so we will have some plastic repairs to do there in the spring. Fortunate that we already have a lot of experience with plastic repairs 😉

We have also started to set up some roof panels, and it is starting to look real good in the boat! 🙂

Service of our “new” Lewmar winches

The other day we started with some service of our “new” second hand Lewmar winches we bought this weekend. During the same weekend we managed to find both bigger winches for the genoa and also smaller, ones that we will attach on the mast for the halyards, on a second hand site.

For the genoa winches, we have been keeping an eye for second hand winches of the correct size for a pretty long time. The winches we have works, but they are really heavy to use, are probably really old and only has one speed. Maybe they would still work better after a thorough service, which would have been our option if we weren’t to find any good second hand winches.

When trying to understand how big winches we should have, we have used the table HERE. From the table it says that for our sail area for the genoa and size of the boat a winch of size 40 is a good size for us. That is a pretty big winch and a new winch of that size costs a lot! So we were really happy when a pair of  second hand Lewmar 43 winches showed up on a second hand site. They are pretty old as well, but probably not as old as the ones we already have. They have 2 speeds but are not self-tailing, which is something we definitely can live without, even if it would have been nice to have that feature.

Two days after we bought the bigger Lewmar winches, a pair of smaller Lewmar winches, of size 7 showed up, which we will use for the halyards on the mast. As it is now we have wire halyard for the main sail and the furling genoa, were the wire is attached to the winch. We have two winches of that kind on the mast, one for the genoa and one for the main sail. They can only be used for one halyard per winch, and as we have a cutter stay as well we have no means to hoist that sail properly, since we only can do it by hand. Our new plan is to remove the wire system and attach the new winches, add rope clutches and new ropes. With this solution we will also be able to use the winches as help to reef the main sail, which might come in handy.

But back to the service of the bigger Lewmar winches (the small seems we only took apart and they are in much better shape than the big ones). We took them apart and inspected all the parts to check if they were in good shape. Apart for some small spare parts that were broken, it looked good. The parts that were broken was a distance between two bearings and a spring. The spring is a common winch spare part, so it is easy to buy new ones. We also cleaned them thoroughly, to get rid of a lot of old grease and other dirt that has gathered in the winches over the years. Next step will be to buy the spare parts we need and mount the winches back together again.

service lewmar winches
Service of our second hand Lewmar winches; taking them apart and cleaning the internal parts, which were filled with a lot of old grease. We cleaned them with white spirit and a standard brush.

We have also updated our sailing plan a bit. Our initial plan was to sail to the Caribbean, leave the boat there and fly back home and then continue sailing later. But as we noticed, a few days after we wrote our budget blog post, was that it is really expensive to leave the boat in the Caribbean. Of course we hadn’t exactly expected it to be free, but it was way more than we had expected. So we had a gloomy couple of days, and had to re-think a bit. Then we realized that we could make our sailing trip a bit longer and sail back to Sweden as well, which felt like the right thing to do once we came up with the idea. Another thing that we like with this new idea is that we won’t leave the boat unattended and all the work we do now will be lost. By sailing back we can continue renovating our boat when we get back as well, sail and explore more of the Baltic Sea and eventually we might leave for another, perhaps longer sailing adventure in the future. If you want to check out how and were we plan to sail, you can visit About->The Plan.

Another leakage found…

Last weekend when we, as usual, were at the boat working we noticed a new place with rotten wood and apparently a leakage from above. We found it when we were removing styrofoam in our aft cabin (see The Boat to see an overview of of our boat). This rot is underneath one of the seats in the cockpit an dour guess is that it is a leak in one of the storage hatches in the cockpit (were we didn’t add any new plastic during our big plastic repair job). But, this is something we will have to do later in the spring. Yet another thing on the to-do list…

But, of course we are glad  that we remove the styrofoam so that we find these things and can do something about it before we leave. We are also really glad that our sandwich hull does not have a wooden core (it is only above the waterline we have some places were there is a wooden core).

But some good news is that we are almost completely finished with setting up all mahogany! 🙂 And it looks so good, Thomas has been very thorough and it really shows. We have also started preparing for setting up som kind of roof panels, which will make our boat look even more fancy. We also plan to set up some LED-lists to put some light on our new hull and to get more light in the boat.

So soon we will be able to show some really amazing before and after pictures. We have also made a slight change of plan when it comes to our sailing route, but more about that soon as well.

Building our own freezer

Before our summer sail we bought a new refrigerator from Dometic (more about in an old blog post, click HERE), instead of making our own, but now we will start building a freezer as a complement to our refrigerator so that we can store all fish we will (hopefully) catch. Next to the entrance under the bed there have been a cooling box previously, so we will use the same space as well, but with some modifications.

First up to do was to remove the old insulation in the box, and the old cooler. We will use another, newer, one we have already, from a refrigerator in a truck. It is a Danfoss BD35F compressor with a plate evaporator that we will mount in the top of the new freezer.

building freezer
Started to remove the old insulation. The cooling box as it was before didn’t have any surface above the styrofoam and some of them were really dirty and it was a lot of smell inside the cooling box. Very nice to get rid of it.
Styrofoam removed and the old cooler.
The box zoomed out.

As we want a freezer we will add more insulation than it was previously in the box, we will also use closed cell foam insulation that does not absorb any water. We will cover the insulation with white-painted aluminum.  This gives us a surface that is easy to clean. We removed some of the wood around the box to make it a bit bigger and since the new top will lay on the insulation.

building freezer

Unnecessary wooden parts removed and measuring how big the freezer we are building actually will be.

The freezer won’t be very big but we are prioritizing low power consumption instead of having a large freezer. This way the food we store here will be kept cold and if it should break for some reason the items will stay cool for a longer time.

During the weekend we have also started to prepare a roof to match our new mahogany strips. Our boat will soon look absolutely amazing! 🙂