Category Archives: electronics

Perkins 4-108 Issues, LED Lighting

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A few days ago we discovered a broken bracket holding the alternator.  It was not something I was going to ignore, and certainly wasn’t going offshore with it broken like I found it.

The forward part of the L-bracket was shattered.  One side (aft) was still holding solidly, and the bolt was going through the two pieces.  However, a broken alternator bracket would cause vibration (which it did when it broke) and eventually would have torn the belt to shreds.

Therefore I called for a mechanic because I haven’t any way to do welds, and it’s one of the skills I don’t have (but I certainly am going to look into learning it now).  I am sure that I could have accomplished all the work the mechanic is doing, and if there’s ever a “next time” I’ll do it.  I’m am not the worlds best mechanic, and honestly, I don’t like getting dirty inside engines.  And since we’re on a dock, and I’m already paying for it… might as well have a professional look things over anyway.  I’m glad I did because I’d never have seen the exhaust leak before it killed us.

Technician came out rapidly (he was on-site), removed the bracket, did some testing and we discovered with our faces in the engine that the manifold was blowing a lot of exhaust out into the engine compartment.  Well, that opens into the bilge and cabin.  Long story short, that needed repairs so we didn’t… umm…. DIE.

He did attempt a repair, put new gaskets in and had the welds accomplished.  There was an extra bracket installed which was causing some of the problems with being misaligned!

But other issues ensued as well.  We noted some oil leaks (but had a hard time finding them exactly, finally he found them and one, the least one, is on the timing cover.  The major one is the valve cover area, and the gasket (after looking at it) is pretty old and ate up.  It’s either original, or it’s pretty old.

On Friday last he said “It will probably be Monday before I can come back”.  We said “OK” and then went and rented a car from Enterprise on their weekend special (10 bucks a day for Friday through Monday morning, giving us almost four full days for 38 bucks).  And Jason called and came back on Saturday to repair things because… he got the parts in sooner. Haha.

Ok, now we’d paid through Wednesday and had to extend a few days.  Today is Tuesday.  We used the car, turned it in yesterday.  Made a trip to Wilmington to find a Radio Shack and some parts I needed for electrical project I was doing.  (I found one, and 45 BUCKS later, I had my little project boxes, toggle switches and a fan for our bathroom and the composting toilet, which I’ll do at a later time when I have all those parts…).

So, it’s raining like hell yesterday after dropping the car, so we duck inside the Dead End Saloon up at the top of the hill to wait out the rain and we run into Jason who is running back and forth from the boat to the truck for tools.

Not good news.

  1. The valve cover DOES need a new gasket, badly.
  2. The timing system isn’t as bad.
  3. The mixing elbow from the exhaust is pretty bad, but we don’t know yet how bad.
  4. The injectors are spitting fuel through (which is what causes the white smoke on startup).
  5. The manifold attachments are missing a couple of nuts, but worse, even after new gaskets and sealing, it’s not good.  The thing has overheated and is slightly warped.

Bottom line, has to be retooled to make it flush again.  The valve cover needs removal and gasket replaced.  The timing area (a bunch of gears connected to the crankshaft) leaks oil and SHOULD be replaced but that’s a pretty big job.  The mixing elbow, once removed is trashed inside. Pieces of it are missing.  Causing back pressure.

So, we need a new one.  I told Jason to go ahead with the work.  We’re going to wind up doing a “monthly rate” here at the marina now I guess.  Only way to save a bit of money now. This is likely going to run about 3000 dollars for the amount of work.  /sigh

Anyway, we should have rebuilt injectors, new gasket on the valve cover, and a new mixing elbow, a replaced bracket on the alternator (and it is now PROPERLY aligned, which it wasn’t, which has been causing most of our issues with belts and vibration in the past).  Right now the engine valve-rocker cover is off and everything is covered with cloths.  Elbow is off.  Injectors are gone.  Fuel is all shut off.  We’re stuck on the dock for a few more days.

I spent today working on our lighting.  I don’t like the incandescent lamps (good for reading, bad for the batteries) and the LED lamps I’ve used don’t give us quite enough light for the interior when it is pretty dark outside.

A few months back I bought three rolls of LED strip lights that work on 12VDC (I had bought a tube of them at the hardware store before that, and discovered they were set up for 120VAC and it wasn’t an adaptor, but rather they use resisters and diodes to drop the voltages down to what LEDs can use, a couple of volts each).  Anyway, I can use the tube lights on the dock, when we have AC power only.  I couldn’t modify them safely to work with DC.  Instead I bought the strip lights and put them in my little project box.

I needed toggle switches and a way to mount them. I considered three or four methods including little project boxes, but Radio Shack is the only place to pick those up (unless I order them online from someone like Jameco, Digikey or someone similar).  I haven’t been anywhere that I could really order things, long enough lately to do it, so… RS it was.

So, I collected parts as I could.  A while back I saw someone else’s work with LED lights and liked their stuff.  It was Acadia, Jon and Marcia’s boat.  He had used little boxes like I wanted to do, and had mounted them using sticky tape (all of the parts are very light).

Today I put everything together and installed strips of LED tape on both sides, under the area where the grab rails run along the length of the ship.  So the settee area is now well lit when you turn on both sides.  I doubled up the starboard side for JoAnne because she sits on the “couch” a lot and reads there.  She has extra light for book reading now.  She loved it.

Starboard Side Lit up

Port side lit up

Another shot of the port side, the mess is the tools, looks like we need to dust again. lol

The next few images show the parts, and some of the tools I used to do the job.  The boxes are simply mounted with “doubled-sided-sticky tape” (the 3M stuff) and I tied the wiring to the existing lamps because honestly, I don’t feel like ripping out the wood that is between the overhead/deck above and the lamps.  There’s a hand full of wiring running inside there and if I take it all out, I’ll be rewiring the entire boat in no time – and I don’t have the time to start that project right now. haha Eventually, but not now.  I want to be able to sit there and read, look at charts at the table and even do soldering (like I did today with my makeshift light you see in the background, which doubles as an emergency anchor light).

The wire has sufficient current carrying capability for very short runs.  I wouldn’t use it for something other than LED lights.  It’s really meant for speaker wires, but it’s 16 gauge and can handle about 3 amps of current.  These lights pull about 500 milliamps (1/2 amp) on either side.  So a total of perhaps a bit under 2 Amps.

Close up of the LED tape strip, and the internal part of the switch box.  The wires are soldered internally and there’s a feed that is attached at the existing lamps using crimp connectors.

Used tywraps as strain relief inside to prevent accidentally pulling the wires from the box.  Since it’s inside of a box I used a bit of electrical tape to insulate the soldered connection.  It is inside a box which no one will see (except here in a picture) so I wasn’t looking for elegant or neat, just “good” and besides, I don’t have any shrink tubing or I’d have used that instead (old electrical wiring habits die hard sometimes).

The finished box.  Double sided sticky tape goes on that side, the whole thing gets “stuck” to the overhead (under the grab rails on the bulkhead) and hopefully will hold for a few years.  I cleaned the surface with acetone before sticking things in place. It’s painted with a flat white paint, so cleaned right up and the LED tape is also “3M” tape so it ought to hold a long time.

LED light strip in “action” – and yes, I noted the damage to the wood in the picture.  Apparently there was a leak there once.  It’s been patched somewhat and I probably should pull that all down and put up new wood or repatch it at least (which means I’ll be pulling new wires in as well to the electrical, therefore, that isn’t happening right now either. haha)

Starboard side, double strips front and back.  Port side only has one strip.

Sometime in the next few days if I get a chance, I’ll do the same thing with the galley area, because it’s in the walk-through to the aft cabin and very dark.  There are four lamps, two under the grab rail area, one behind above the engine, and one on the over head.  None of them provide enough light for the galley, or working in the galley, so that’s going to change soon.

Hurricanes and Boats

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Simply put, hurricanes and boats don’t mix well.

Matthew is proving to be a pain in the ass for a lot of folks right now.  People in Haiti, soon Cuba and then the Bahamas.  After that, according to the models (which I want so desperately to disbelieve) Florida, and most of the East coast of the United States will be in for a bit of roughhousing as well.

Latest Tracks for Matthew

I’m far enough north that it should break up and just be a tropical storm by the time it gets to us, especially if it hangs over land for any length of time.

But for whatever reason (I can’t see the reasons) the models have pushed over to the west and it’s promising to be a beast.  I see a front coming through, and pushing out, and now there’s a dry, low pressure system in the middle of the US which may reach the coast about the same time, and that might be pulling the hurricane in somewhat.

On the other hand, there’s a mess of rain and another front west of that high.  It usually takes 3-4 days to cross the states with weather systems.  Hmmm.  MAYBE it will get to the coast in time to push some more.  I don’t know.  I’m not a forecaster, just a storm chaser that looks at the data and predicts local mesoscale conditions.  Hurricanes are big, bad, Red-Spot-on-Jupiter things to me and are as distant as that planet is from Earth for me.

I’ve been in two.  One hit DC a long time ago and water levels came up 8 feet up the Potomac and Anacostia Rivers.  The second was in Jamaica in the 2ooo, when it missed us by about 90 miles on the north coast of Jamaica. But… it RAINED like the ocean was pouring over us.  I’ve never seen so much rain for so long in my life.

The plan today is pretty simple.  Down comes the headsail and sheets.  I’ll remove everything off the deck and bring it below today and tomorrow.  And we will bring our tarps (we use as tents topside) below to cover things down here inside the boat.  JoAnne will pack and we will be ready to bug out sometime on Saturday morning most likely, because the predictions are showing it coming up this way Saturday night and Sunday morning.

The last of the preps will involve moving the boat out, adding lines and hoping for the best.  We’re not going to stay aboard the boat if the hurricane approaches us.  We’ll head inland and stay out of the path as much as we can.  I’m planning to take most of our clothes, our foulies, food, water, electronics, important papers, car and our mortal bodies away from here.  We went through a Nor’easter in the Bay… and that was not good, with the shallow Bay, short chop, poor JoAnne getting sick.  Staying in a Marina is not going to be much better.  And there’s little here to keep us safe, and in fact, it might be pretty unsafe to remain here.

I maybe take one of the ham rigs too, just in case.  We have terrible luck with the phones, so a ham radio might come in handy.

So, all my hoping and my “estimating” isn’t coming true.  All I can say is that the hurricane tarried a bit too long in the Southern Caribbean Sea and the weather that would have push him off is long gone now….

This sort of thing is, by the way, why I have been a “prepper” most of my life and even wrote a book about it.  I sure hope it all works right this time. 🙂

I guess that’s it for now.

If y’all believe in prayers… better get busy.  The entire coast of the US, Bahamas, Haiti and other poor people in between are all in danger’s path.

Refrigeration

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Refrigeration:

Our boat, Adventure, has an ancient Danfoss D2 unit. I took pictures of it awhile back and posted them here. Today I troubleshot the major issue, no power. I found that the unit’s ground was wired through a “dead” power supply, the boat’s auxiliary battery charger. I SUSPECT that unit was disconnected at some point when the newer unit which is a charger/inverter system was installed. I KNOW there are some wires going back to the batteries that are no longer connected and MAY go to that charger.

Anyway, because the charger won’t fire up, the ground is removed from the fridge.

So, I pulled the old red (+) wire from the unit, and tied a new cable with both black and red wires, and used the old cable as a fish/messenger wire. Pulled in the new cable, made the connections in the panel, then tied everything in at the compressor.

After I reinstalled the fuse and checked the connections, I fired up the “Refrig” breaker, saw the compressor kick up to a momentary 8 amps, and drop back to 5 amperes.

I listened to the cooling plates and sure as I’m sitting here at my computer, I could hear the thing pushing fluids through the plate. In five minutes the plate started getting cold.

It’s been on for 10 now. The temp inside (and remember we have been putting ice in the unit as an ice box for a couple of weeks now) is around 54 degrees F right now. The plate is developing some frost on it, which it would NOT do with just the ice in there.

That means I can pronounce the patient “healed”.

I do need to replace the thermostat, as it is broken and in some random position. I also need to run this thing to see how cold it gets for a couple of hours.

Update to follow!

Update July 1: C-Head, Solar, Sails, HF Radio

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C-Head:  Over the course of the past couple of weeks I have been busy digging in the lockers, getting parts together, ordering things and repairing a few things.

We ordered and receieved the standard “C-Head” toilet a couple of weeks ago.

Unpacking it was easy.  The parts inside are standard parts.  The most expensive piece I suppose was the C-Head container which is a box like plastic container.  It holds a standard sized 5 gallon bucket which has been modified for use inside, with a frame that holds a paddle that you crank around to mix up the composting material.

The number 1 bucket (pee bucket) is a simple 1 gallon water/milk jug.

The device is well built, but personally I still feel it much more expensive than it needs to be.  Everything can be back engineered however to make your own if you wanted to.  In our case, after looking over the forward head, that appears to be our next option.  I’ll just reverse engineer this thing to fit a new, home built device in the forward head.  Reason being is this standard one will not fit.

Installation was easy.  Taking the old electric head out was a bit more difficult, but it took me a couple of hours.  I still have not actually removed the hoses.  I plugged them all, and left everything in place “just in case”.

The new head doesn’t quite fit right, but after playing with the various angles of the head we were able to mount the toilet in there.  It’s been in use for over a week without any issues at all.  I make it a point to empty the urine jug daily though.

So far, so good.  It doesn’t smell at all, especially not like the still-existing holding tank.

Wiping it down is easy.  Emptying the tank is easy.  I have yet to attempt the emptying of the bucket (the “Number TWO” container, haha).  That will be soon so I can make sure it’s done once and I’ve gotten the hang of it.

Solar:  Solar panels and some parts arrived a week ago as well.  I have installed them on the Bimimi frame.  Unfortunately, I don’t have the money to buy all the cool, fancy stainless steel fixtures I actually needed, which would have been clamp on stand offs.  Instead, I manufactured my own.  Cost me about $20 dollars for stainless steel bolts, nuts, washers and some aluminum stock (yeah, I know steel and aluminum don’t mix in sea water, but these are physically under the bimini anyway).

I will add pictures when I have time to this blog entry.  I have to take them, upload them to the host, then post the images in the text here.  It will not be today.

The solar panels are working very well, but, they aren’t hooked up, so there’s no place for all that beautiful sunlight to be stored as electricity at the moment.  However, the Charge Controller is mounted already in a closet in the aft quarters.  I have a plan together to run the wires through an existing deck entry which contains an apparently non-working GPS antenna.  I’ll be tracing wires shortly to make sure it’s not being used somehow.  There’s a second one mounted on the aft taffrail area, and it blinks a green light when operational, orange when searching, so I’m pretty sure it’s the operational antenna.

Here the charge controller is wired in and operational.  Taken 2 July 16 at 0800

Yesterday in the US Postal mail a letter came addressed to me from Dick Stapleton who used to own Duna.  Duna is now Adventure (and we did have a naming ceremony and all that, in case anyone wonders).  In the letter was a very short note on a yellow sticky from Mr. Stapleton.  The most important part was the single sheet inside the envelop.  It was something that engineers love.

An electrical schematic for the sailboat’s systems!  I had been mulling over how to trace everything and this schematic is pretty accurate from the parts I already chased down.  The only thing different on the schematic I can find is the fact that there were only two 6V batteries when we purchased the boat, and there are four of them now, in two 12v banks tied in parallel.

Funny part is, the schematic shows four batteries.  So, now it is about as accurate as I could have drawn it.  Obviously there aren’t all the connections shown on the page, but it does tell me a lot of things I was unsure about, like the battery/service/engine switch and how it actually was wired.  I checked it last night and the meters and sure enough, it’s wired as it says.

Tying in the solar panels will be simple, or rather, relatively simple.  I need to feed wires down below from the panels, I need to attach connectors (some of the parts I bought) to tie the panels to the controller.  Then I need to feed wires from the controller over to the batteries and tie those in.  Pretty much all I need to do.  I could add a small inverter to the load link, in case we wanted to have a separate AC load in the bedroom area, but I’ll consider that later.  I do have a 400 watt inverter we carry in the car when traveling and might put it in the bedroom as back up to the large one.

We have a several hundred watts inverter in the boat.  It’s part of the Xantrex Heart monitor system.  I’ve not really taken a close look at it, and don’t remember the model, but it is capable of running a fridge, coffee pot and a few others things, but not necessarily all at once.

Thanks to Dick Stapleton for sending that schematic.  That was very helpful!

Sails:  All of our sails are roller furling sails and the main and mizzen live inside the masts, on a furler built inside.  A few weeks go when I looked over the sails I realized the UV covers were in tatters and weren’t really doing much any more but flapping in a breeze, so Kurt Seastead, the owner of the Transworld 41 Facebook Group  suggested I contact Ullman Sails and drop off the sails for repairs.  Instead I opted for them to come visit the boat, help me take them down and look things over.  I ended up sending the working jib, main and mizzen sails to have new covers installed, repairs done and so forth.  Wasn’t cheap.

Yesterday I drove to Deltaville VA to collect the sails.  Unfortunately, they lost the one bag I have for my sails, but were nice enough to give me a new one as replacement.  Thanks Jerry!

They did good work.  I wasn’t happy that they called me later to tell me they “forgot to charge me for the washing” – because the initial conversation said “wash, repair, etc” and then I got the invoice later and it added a few hundred dollars to the bill I wasn’t expecting.  Other than that over sight, things were fine.

Until I went to install the mizzen sail.

Apparently the halyard was weakened near the bottom.  As I hoisted the sail something bound up and before I could reverse everything, the halyard snapped just inside the mast opening.  I had my hands full of broken line, winch handle and suddenly sail…. the sail pulled the halyard up and out of the mast assemble, leaving me with no halyard inside the mast now.

So, until I either get up the nerve to climb us and thread the needle, or bite the bullet and hire someone, I’ll use the outside track and spare halyard to use the mizzen sail.  Might be easier anyway.  The thing always seems to bind or act funny.  Putting a sail on in a NORMAL manner might be a change of pace and give me a chance to actually USE the mizzen now.

HF Radio: JoAnne and I are both Ham Radio Operators.  She is KB0IRW and I hold call sign N0NJY.  She doesn’t really do much with ham radio these days but used to get on the VHF and chat, or do Skywarn stuff in Colorado.  Since we started refurbishing the house a couple of years ago all my ham gear had been packed up and disconnected.  I don’t even have a rig in the car any more.  The only times we’ve used it was around marinas to talk to each other or in the car traveling on the handhelds.

So a couple weeks ago while waiting on parts to arrive, I ran some wiring back to the backstay antenna and connected up the HF rig.  I have been able to do a bunch of contacts on a digital mode called BPSK31 on 14070Khz with numerous hams around the US, Caribbean and even Europe.  The rig is only Amateur Radio and I don’t marine HF (SSB as the mariners call it) right now.  Going to change that soon.

The reason for having HF in the first place to call for help if we get into trouble, or pass email traffic through Airmail and a pactor modem.  We don’t have a pactor modem though, so I use a Tigertronics SignaLink external sound card (box) connected to the computer to feed data in and out of the laptop.  Using linux as my OS.  One day, I’ll write about that.  Should be educational if not boring as hell. Ha!

That’s what’s been going on lately.  Well, off to dig in the bulkheads, cabinets and wiring to see what’s actually connected, and what isn’t, start pulling in wires, and get these solar panels doing what they were designed to do… give me MORE POWER!

 

LED Lighting

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I decided to drop a few bucks at Lowe’s yesterday on a strip of LED lighting in the hopes I could made a simple mod and run them on 12 Volts DC.

Unfortunately, that didn’t turn out to be the case.

After looking over the connectors I found that the lighting was designed around LEDs, which is nice, but the little “adapter” which I assumed (wrongly) would be a simple step down transformer, going from 120ac down to 12vdc was not.  Instead it was a device (called a rectifier, a set of diodes really) that converted the voltage to 120vdc instead of dropping it down to where I could use it.

In other words, the lights weren’t designed (probably purposely) to use low voltages.

So… no easy modification there.  But, on the bright side (see what I did there? LOL) they light up the cabin pretty nicely.  I can really only use them on shore power as I wouldn’t waste the battery power to run the inverter to run these lights.


I promise, they aren’t throwing out lightning bolts like a Tesla Coil. Though it looks cool. haha


One image showing part of the lighting.


Different image showing the rest of them.

Later, I’ll go on the hunt for strip lights from Amazon.com because they have everything a electronics geek could want to play with!