In this week's episode of Onboard Lifestyle we re-engineer and assemble the rudder linkage on our custom 435 catamaran SV basik. Come back next week when we ...

Closed Captions (CC):

[Music]

good morning welcome back this ebay

thing

sun's out now but it rained all night

long but it doesn't matter rudders are

waterproof start to put these back

together now it's the linkage I need to

get all this Hardware back and installed

but there's a lot of little missing

pieces and things that I've had to

change so I can take advantage of a kind

of a blustery morning let the decks

dried a little bit and run some errands

so we'll get some parts I get this thing

going okay I got a lot of little bits

and pieces to come up with it's gonna be

impossible to predict what I need all at

once so we're gonna do is just kind of

tackle this and little segments I know

what I need to get started with so I'll

start from there okay first stop Ballard

industrial need to pick up some

stainless

okay just picked up stainless observe

fittings and stainless key stock now off

to fisheries to get some nuts and bolts

okay go into a little machine shop here

and having this 1 inch stainless cut the

lane

okay run enough errands for this morning

it's nice out get back to the boat

getting tired of dragging my Capilano

around everywhere but got some parts not

to get started so I'm gonna start

tearing into this linkage just paste by

piece

here we are now that I have my stainless

key stock set up a little cut station

here on the dock and I need to cut six

of these for the linkage so let's be

going to that

[Music]

[Music]

okay my keys are cut let's see how I did

here not bad hey there you go

close enough shooting for one inch now

I'm gonna take the shafts that were just

cut at the machine shop and clean up

those edges okay next thing I need to do

is grind in a slot to accept my quarter

inch key stock right here I'm just gonna

hand do that with a grinder

look at that with grinding skills like

that I could I could come work with you

seeker I'm happy with that

that's good okay

we've been starting to modify the

linkage cutting them down and just kind

of trying to make this work remember a

few weeks ago I polished all this up try

to get this in good shape I'm starting

to cut things down modify pieces and

we're gonna try to put this all back

together this is just to some of the

smaller pieces we've got some larger

pieces laying around as well now you

probably wondering why do I have to

modify the linkage the rudders haven't

changed these are the same well this is

why you have to flash back a couple

years here is our sugar scoot

see these stairs these weren't there

before just went straight from this

level all the way down to that level all

the linkage for the rudder system was

open and exposed you can see everything

now I tried to bury as much as I can

inside of the steps here unfortunately I

couldn't bury the last little bit see

how far back the rudders are set they're

sent right at the aft of the vessel here

so for me to bury that last little bit

of linkage I would have had to raise

that step up about another six eight

inches off the water and right now it's

still about it I don't know 12 14 inches

off the water now wanted to get ladders

in here make it easy to get on board so

that forced me to leave that step down

we're gonna have a couple feet of

exposed linkage but the rest will be

buried inside the scoop now so that's

why we're re-engineering and redesigning

things we'll use some of the pieces

we'll have to cut a bunch down kind of

designing this in my head as we go

hopefully it'll all work I'm sure it

will we'll make it work

so let's get putting this thing back

together okay I need to put these on

here but I just took these old steel

zerk fittings off and bought new

stainless surf innings so I'll get these

replaced if I put them in

nice and easy these are the first two

arms that come directly off the rudder

post there's one there pretty beefy but

there's a lot of forces there so I don't

mind okay this is the key stock that I'd

cut yesterday those 1-inch pieces this

is the first piece to put in here read

this off to plus oh crap mail

he needs energy yeah that sounds more

like compass okay my arm should slide

right on over the key there we go

and tighten this up

Oh

[Music]

okay the first rudder arms are in

you guys I offered to help teal and

assist him with whatever he needed and

he took me up on my offer I didn't think

that was actually gonna happen so he

gave me a cut list this morning and said

I need to go find some machine shops to

see if they could do it I don't even

know where machine shops on around here

but I'm gonna just google it and see

what works not only did he give me a

Cutlass he also gave me a list of things

that I had to go pick up so he's very

specific making sure that I get the

right product locking nuts really kind

of funny am i you're in charge of these

okay we better not screw this up yeah

the thing is is I don't even know where

I'm going so hopefully we'll get back by

this afternoon but he's hoping that I

can get this done in the next hour or so

so fingers crossed that we can do this I

think we can yeah okay Emma this is a

little confusing I can't figure out

where we're supposed to be jog right

onto 16th Avenue West I know

probably lost well we're not lost the

directions are telling me something

different because I do it right on the

16th Avenue West okay this is not right

okay I'm not gonna listen to the

directions anymore cuz I think they're

wrong

actually I know they're wrong so we're

just gonna find it it has to be right

around here because because that's what

the shows on the map oh don't tell

we found it

we're gonna go to see how machine works

first and see if they can help us this

serious machinery

okay so that projects done you guys

Seattle Machine Works was awesome those

guys let us tour the shop and really

helped us out and got it done so score

yeah

we're really happy about that so now

we're heading yep so now we're gonna be

heading over to the second stop which is

to come a screw to find that bushing so

I hope that we luck out there like we

did here and get it all done first thing

this morning okay

okay so that was the past Tacomas group

did not

pushing that

but then they did suggest that we go to

fisheries officially would have it which

works out for us because that's where

we're headed next anyway so okay we

struck out but we're still pushing

through ok so now we're at Fisheries and

hopefully we get all the parts here and

then we can make it back to these things

what do you think fingers crossed got

all this running around is

time-consuming did you find it yeah how

many do we need

so we struck out on getting that nylon

bushing or that reducer but we did get

all the nuts and bolts here they did

give us some suggestions on where we can

find that reducer so we're off to

another stop I can't believe it

we found that last bit and it was here

of all places so I'm excited to give

teal some good news that we got

everything on his list because I think

he was trying to stump us so bright you

know let's get back to the boat um you

drive

okay making little progress here let's

take a look at this I take these six

pieces and assemble them to make this

let's look at this these go in the sugar

scoops and what these do is pivot they

transfer the energy from the tie bar 90

degrees to a strut that goes to the

router there's two of these one in each

sugar scoop and they're connected

together and these keep the rudders

running parallel didn't take too long

put this together and I'll put this one

together now and probably call it for

the night it's getting late

[Music]

okay there they are we'll get these

installed tomorrow and good morning it's

a beautiful day but you know what I woke

up at midnight thinking about something

this nut on the bottom of this right

here and how far it hangs down I knew

this was gonna be an issue and why it's

an issue let me show you on the swim

step

I added a boarding ladder and I knew

that that arm is gonna get real close to

this bracket right here I knew it'd have

to put a little notch in there but that

bolt creates quite the deep notch so I

got to thinking I laid awake and figured

it out all I have to do is swap this arm

with this arm it doesn't affect the rest

of the linkage but what it does is it

gives me a lower profile here and I

could use a pin to hold it and retain it

rather than that big bolt it gives me

about another inch of clearance so I'll

swap these off-camera and show you how

it turned out okay just like that swap

the arms out

and put this back together

I'm gonna start working on installing

those

but I pull that little project for Lynne

I'm breaking this down right now getting

all these old hoses off all the rusty

pieces I've lubed all of it but Lynn's

gonna polish this up this are hydraulic

ram for the steering so I guys start

laying this out make sure all this is

going to fit

hey Linda died awesome job cleaning this

up look at that while she was doing that

let me show you what I was up to

first of all I put this half store in I

also had to cut in a deck plate here I

needed access through this bulkhead to

get my hand in to tighten some hardware

that's underneath of this let's go

inside so it looks like okay there it is

right there

reach up in here it's all bolted in

place here's the arm that goes to the

type r and down here this one right here

see point to this one that's the arm

that goes to the strut to the rudder so

now when this rotates back and forth it

transfers that load to the rudder this

wasn't too bad to put in let's jump over

those sign I'll show you how I did it

okay the first thing I want to do is get

this hatch and permanently just so I'm

just gonna mark out the holes with butyl

well actually sorry semi-permanently

because eventually we're gonna paint

this entire locker and I won't be able

to remove it so I'll use butyl tape on

this I want this in first for a reason

when this doors in the open position I

won't be able to clear this deck plate I

did have this hole here in this bulkhead

I know I didn't do a repair on this

knowing that I'd be cutting a deck plate

in here so I didn't want to waste my

time filling this hole so now that this

is in I can mark this out and make sure

that I miss that when I drill my hole

hatches in here's my mark my hole saw

make sure I cover up the hole here

nugget mark my Center will get this

drilled out

it's nice having a hole saw and look at

this hole saw no teeth on it's an

abrasive edge on here but always pick up

a hole saw that matches like knitting

makes them just perfect fits every time

now let's get some screws in this fasten

this up I'll also put a little butyl

tape behind this because this is a crash

Locker I want to make sure if this thing

ever does fill up with water it's not

leeching around this deck plate okay

let's get this mess cleaned up get all

the dust out of here wipe down all the

surfaces and get going in here

okay much cleaner in here okay let me

explain something out of this entire

sugar scoop all this structure around me

looks like is all new this is part of

the steps coming down the only original

part was this polecat came up to about

here somewhere Matt brought right here

and I filled the rest of this in up here

the only other original part in here was

this deck up here and I left this just

sticking off of this wall here for years

and I did it for a reason because of

this hole I wanted to make sure this

hole didn't get lost that hole is very

important

all the linkage pivots on that hole by

keeping that like this insert my sleeve

and it gives me my mark now I just plumb

straight down and I put my other fitting

down here that creates my pivot point

for everything to work off of so let's

get these in

okay hep plunked down marked it out and

drilled put some butyl tape on the

bottom of this because this is a area

that we'll see a little Walker please

[Music]

the narrow I could reach through my deck

plate and put the fasteners on the

bottom this is in permanent before I put

in and I'm dropping a one-inch washer in

the bottom of this just in case this

ever slips down I don't want him wearing

on the glass he'll ride on that washer

you should never do that but just in

case

[Music]

[Music]

okay just like that is in

okay I feel good oh I think I'll start

cleaning up my mess and enjoy the rest

evening uh I thought I was done cleaning

up my mess and I found this this is the

stop that goes up here this whole

mechanism can't go down because of this

arm but it can go up cuz this much play

in the shaft suck to break this all down

and put this in okay another my lesson

get this fixed okay now I feel good

about it now I'll call it

okay I gotta start preparing hit this 20

foot plus type are thought to drop the

dinging

okay let's look at my project for today

look at this the tie bar has moved

multiple times over the life of this

boat cannot wait to haul the boat out

and get all this cleaned up I'm gonna

shave all this out polish this up get

new paint on that bottom side here new

bottom paint huh

it's driving me crazy but it's coming up

fast but we need to do is I'm moving the

tie bar back to the original position

which will go through those holes in the

hole there but this diameter is a little

undersized I have to increase this

diameter so that's what I'm doing today

okay that actually went in pretty smooth

got that hole drilled out on both of the

sides here and looking into this it's

actually an epoxy core so somebody

actually oversized a hole filled it with

epoxy and then inserted their sleeve

that's exactly what I'm gonna do and I

did I oversized a hole not knowing what

the core was so now that I'm happy with

it

I'm gonna take my PVC insert and epoxy

this in poxy actually sticks real well

to PVC I like to scuff it with a coarse

sandpaper first and I'll epoxy this in

let it cure overnight and sand this

smooth and hopefully I could do a better

job on this insert then the previous

owner did on this insert okay I'm all

set up Glenn's mixing me up some epoxy

yep I'm ready it's gonna kick in the

side okay thank you

okay let's get the first one in

okay I've buttered the inside now I'll

insert the tube and then inject

thickened epoxy from both sides it

wasn't too bad

I have the inserts all up hocks it in

will let these fire off tonight

call sand them smooth tomorrow okay

these fired off overnight trim these

flush and then sand them smooth

[Music]

not too bad let's take a look at these

these sleeves are already now it's just

a matter of positioning that long tie

bar on the deck and then threading it

through all the way through the boat has

to go through one two three four five

different holes in the boat so we'll

line that up and get it going

a feat of this way

okay guys ready I'm gonna lift this up

get a good grip pick it put it up over

your head as high as you can

straight up and I'm gonna hold it steady

I'm gonna push you guys out real slow

okay now I got a line you up need to go

south a little bit south

get right about there okay here's where

it gets tricky I gotta push it in a

little bit

okay hold go oh don't pull it out okay

let me go inside okay now I'm gonna feed

this through the linkage Channel okay

lift it up right there

[Music]

okay now it's just a matter of put my

retainer there we go

one down

I'll let Lynn to the other side okay

girls it's in

it looks bizarre doesn't it right there

I just want to say that the basic crew

is running on all cylinders now not much

time left we got a lot of projects going

and no matter what these ladies so they

seem to just get it done it don't and

don't think that we forgot about our

weight loss challenge I have unloaded

502 pounds off the boat so far and this

weekend is the boaters flea market so

don't think I'm not gonna unload another

3 400 pounds easy easy well anyways guys

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