The rebuild of Tauhara  
       
   
       
  In April 2004 Tauhara was lifted out of the water, scraped clean of years of antifouling and transported to the shed we built in the corner of the property.  
           
  It took until August 2004 to get the hull empty and reasonable clean. It took a 2 ton truck 4 trips to the tip to dump the interior, even though useable bits were kept.

 

A work space was created next to the boat on deck level, 3 meter above the ground. A 5 meter workbench with a bench saw was on it, plus most of the tools.

 
 
  Next a mock up was made, using 15 sheets of very cheap ply. Most of the interior was designed this way. The cockpit was only a half model, to allow easy access to the rest of the boat.


Not much has changed since then. Bit by bit the mock interior was replaced by a real one.



All interior is in Kauri, Fijian kauri in this case, since there is no New Zealand kauri in plywood form.
 
 
   
 

Forepeak

Laminating the sides to get rid of the step in the deck  
           
  In February 2005 we sold our house and had to move out. The new house was not ready yet. For the next 8 months no work was done on the boat. There was a lot to do before we could put a new house and all the animals in a 10 acre paddock. The house arrived on 15 April. Floors had to be laid, decks built, cabling done etc  
   
  After a nice relaxing holiday in Rarotonga, I slowly started building again  
           
    28 November 2005


The galley is coming away quite nicely

 
   
  Building the cabin sides out of 4 layers of plywood Laminating deck beams  
  March 2006.


It starts to look like a boat again. Most deck beams are in and some beams in the cabin have been fitted. The cockpit is a waiting game. Waiting for people to deliver the goods they promised like tanks, brackets for the shaft etc. All of that disappears under the cockpit sole
 

 
  Finally all hardware is complete.

The engine sits in its final place. The shaft bearing is fitted, the stern tube and the strut. The diesel tank is now lowered behind all this and the lid closed.
 

 
  6 May 2006  
  The Cockpit is taking shape
 

End of May 2006
 

 
  Early July 2006  
  August 2006


The cabin roof is now closed, the blocking for deck hardware put in and all remaining space filled with polyurethane foam. 2 layers of plywood will come on top of this
 
  2 September


Most of the deck is on, although only one layer of ply. It will need 2 layers. The ends have seen some work done too. Its easier now than wait until the deck is on.


Once finished there will be 33 sheets of ply in the deck and cabin roof

 

 
           
   
  Time for some relaxation. Rarotonga is still as nice as it was last year!  
           
   
    Mid October 2006    
  A lot of work is going into the ends of the boat. The more you do without a deck on , the easier it is. So all steering hardware, including the brackets for the autopilot, are fabricated and mounted. The whole lot gets a few coats of paint too. The anchor well gets treated with 4 layers of epoxy and some glass, to make it watertight and resistant against abuse by the anchor chain.  
   
    23 October 2006 The ends are covered. The deck is closed    
           
  6 November


The dodger is getting into shape. Pads for winches and stoppers have been fitted. The main entry hatches have been made and fitted

 
  16 November  
           
   
  14 December

A lot has happened even though it is not that visible. The shed has been modified and scaffolds built right around the boat. A lot of sanding has been done to fair the new timber in with the hull.

   
   
    6 January 2007. Ready to be glassed!    
  21 January


About 80 sq meter of glass has found its way onto the boat and has been covered again by a layer of epoxy

 
  Sanding, sanding, sanding.....


A nice opportunity to check the fitting of the windows
 
  27 January


Lets join the Navy. Why is undercoat always gray??

 
  A day later......


That looks a bit better. Almost white this time

 
    10 February


After acres of sand paper and many hours of hard labour, it does not really look good. But it sure feels good!
 

 
  After the first coat of undercoat we are in battleship mode again. But it looks good already!  
  The battleship grey has been overpainted with 2 coats of white special filling undercoat.

 Most of that will again end up on the floor!
 

 
    19 Feb 2007    
   
  The keel also gets a cleanup. It will be sealed in epoxy and glassed. 5 March 2007
Finally after a lot more sanding and another coat of undercoat (also sanded again of course) it was time to put the first layer of real paint on the hull.
 
 

And it already looks good!

 
  The next 3 weeks we battled with the paint. It did not work the way it should. It looked OK, but not perfect. So we sanded it all smooth again and had another go. We did the hull 3 times and the top twice. We were not happy. We decided to buy a tin of another brand and put it on the top. What a difference! We lightly sanded it and put up another coat the day after. This was it. This was how it should have been. Today we put a coat of the same on the hull and it sure looks good! (26 March 2007)  
   
           
    The Mother of all Floods    
   
           
  Another delay in the boat building schedule. You are looking at our lawn from the deck. The container in the background is trying to float away. Luckily there was a roof attached to it, so it more or less stayed there. We lost numerous bits and tons of plywood, which was all stored under this roof because the shed needed to be clean. The boat had its keel wet, up to half a meter. All fences on the flats were gone, the bridge disappeared and tons of rubbish and silt were left in its place. And all that while we were ready for the final coat of paint!  
           
 

By Easter we had the shed cleaned up, a fresh load of metal on the ground and finally the last coat of paint applied.

It looks great!

 
           
 

21 April 2007
The next thing is the teak deck. That will take at least 6 weeks to do. It is a lot less dependent on the weather than the painting was. Anything over 10 degrees will be fine. The epoxy will set anyway. It just takes longer!
 

 


Progress in 2 weeks!

 
   
    20 May. Most of the teak is on!    
   
    28 May Just the piece in the middle and finishing the hatches!  
   
  18 June 2007
After all planks are glued on, the seams are filled with black epoxy. That took a whole week with a syringe that would frighten a cow! Then the whole deck was sanded to a smooth finish. The blobs visible on the picture are air bubbles filled again with epoxy.
   
   
 

The finished result!


Now the cockpit.....

 
   
 

9 July.

 
Apart from a few bits of sanding the cockpit is finished. Because of the weather some parts had to be cured inside the house, but in general all went well. There will now be some hardware fitted to the boat before continuing inside.

 
           
   
 

26 July
Fitting the windows was a bit of a challenge, specially clamping them. Luckily there was a shed around the boat. All hatches were fitted so the interior is closed off. That means the heater can be switched on inside.
 

 

 

How many clamps can you fit on a floor?

All of them!

 
           
 

20 August

The floor boards are all in now. More importantly, the things you don't see, like the plumbing, piping for cables etc. Also everything under the floor got painted white, so it will be easier to clean and to see if it needs cleaning.

All hatches have been fitted, although they still need locks, so the don't fall out if we turn turtle. (Worse yet, the beer may fall out).

Next is finishing the furniture. In the front the bar is taking shape, flanked by the basis for the stereo, a sizeable Subwoofer.

One compartment back the chart table is evolving. A lot of fiddly bits in there. I have to get the layout right first time, since I don't want to have to modify it later. It has space for a full size Admiralty chart on the top, a dedicated space for the navigation computer and lots of storage under the lid for paper charts.

Above the chart table switch panels, instrument panels etc will come once I figured out how I want it.

 
   
           
 

Some deck hardware has been fitted too. The genoa tracks have around 50 machine screws all the way down into the hull timer embedded in epoxy. I hope to never have to replace those. Needless to say you can lift the whole boat up on these...
The gates worked out nice. They were even exactly vertical without having to modify them.

 
 

1 October.


There is not a lot to see on the pictures but believe me it sure looks different. The main cabin is finished. All edges are on, door trims are done and all is sanded and polyurethaned several times.

The fridge box is almost ready to go in. Toerails have been made and fitted. A stainless piece of art is lurking on the bow. A lot of little jobs done.
 

 
   
  29 October
The chart table is finished. Some expensive items have already been mounted. The big closed door will get holes in it where radios etc will poke their noses through. We haven't got those yet. Under the chart table will be the power converters etc. All wiring will terminate somewhere behind all this and will get connected to switches and batteries.
 
   
  The fridge has been built in. Around the inside box is on average 100 mm of polyurethane foam. In the locker under it a water cooled compressor will be fitted. The doors will be a challenge to make..... Also the entry has been upgraded from some four by twos to a decent stairway. It also hides the iron sail. There will be a berth in the back cabin next to the stairs. I just put the floors in for it.  
           
 

It is now December and a few very visible jobs have been completed.
Some very expensive shiny stuff found its way to the bow.

Also the Galley has been almost finished. There will still be some additions once we know exactly where everything goes.

And last but not least the hull has been brightened up, first with lots of news papers and now with a decent stripe. The first coat looked like lipstick, but it got darker with each of the five coats we put on.
 

 
   
   
           
  Finally the shed has been cleaned out. All scaffolding has gone and so have the supports for the boat. Oops! Fortunately I bolted the hull to the shed before that was done. When you step on the boat now, the whole shed wiggles.....  
   
 

The whole hull was now sanded, filled where needed and coated with epoxy based undercoat, about 2 layers, some more in places.
I decided to get an antifouling that would last longer than the standard season, to prevent having to haul out in dodgy and/or expensive places. After a lot of research, I decided to go for Coppercoat, since it had the best references on the Internet, mainly from people who were very happy with it. One cruiser had it for 17 years and it still worked.

It involved Jim and me coating the under water part of the hull 4 times in one day. It was almost dark when we finished. I hope it was worth the effort.

Also a good view of the new rudder. We also coated the prop and shaft after treating it with undercoat. It may just work!

 
           
   
           
    Happy New Year to you all    
           
  17 January 2008     The Big Day Out !!      
  The front door of the shed is being opened  
   
   
   
  After opening the shed, the truck moves in with a big hydraulic trailer. The boat gets lifted off the blocks, secured and off we go. It took about half an hour to get to Opua, having made some special arrangements to get through the road works. There she was hoisted off and thrown into the water  
 

Paul and the boys were ready waiting with the mast. A big crane had to come in to put this 20 meter piece of metal into the boat..

 
   
  After fitting some terminals to temporarily secure the mast, we got towed to the marine where the work will continue...  
 

It is now April 3rd. I did not update the website, since there was not a lot to see. A few kilometers of wire has been pulled in and connected. Plumbing and pumps have been installed. Teak trims have gone in. Sails have been added and a lot of invisible things have been done.
The soft bits have been put in and tried out, including the new bed.

At the moment the cupboard doors and the table are still missing, but they are being worked on in the shed.

The launching party will be on 3 May and she has to be ready for it then!

 
   
   
           
    3 May 2008    
  On our way to the Opua Cruising Club, where the official launching ceremony will be held  
   
 

Speeches were held. The original owners of Tauhara presented us with a reproduction of a painting of Mount Tauhara, which will find a place on board.

And then the big bang....

 
     
           
 

We have been living on Tauhara now for over half a year (January 2009). Here are some pictures of the interior and a few at anchor and while sailing (courtesy of JP).

 
           
   
   
   
         
 

 
           
 

 
           
           
    January 2009    
           
  With the limited sailing we had done up to this time we found that the autopilot had problems steering the boat specially running with 20 plus knot winds. Manual steering would would, but with excessive rudder angles. To address this we decided to increase the rudder size. Making it deeper made more sense than wider, so deeper it was. Since it would be hard to weld more steel in without wrecking the existing rudder, I decided to use carbon fiber as reinforcement. The added advantage is that when something big would hit the bottom part of the rudder, it will just break off, leaving the original one in one piece. Here some images.  
           
   
 

 
           
  The result was better than hoped for. The autopilot has steered the boat around the Pacific for 6000 miles and the few times I decided that I should take over, I quickly passed control back to it, since it simply did a better job that I. Even in 40 knots with just a reefed mainsail it steered without a problem.

The other problem was going astern. It basically did not work. The boat would go sideways with lots of water movement and the engine would do full revs without moving the boat much. It looked like the folding propeller was not opening properly, possibly because of the skeg and the slightly offset position of the shaft. We decided to get a "KiwiProp", a feathering prop with composite blades. (www.kiwiprop.co.nz). The result was astounding. When lowered back into the water, I put the engine in reverse and we shot out of the travellift bay at high speed. We never looked back!

 
           
 

 
           
           
           
   

February 2010

   
           
  During our Pacific trip we found the boat a bit tender. It would heel more than it should for the wind speed. Maybe the rebuild had made the boat too light. It was still floating well above the waterline with full tanks and food (and drink) for a year on board.

To address this we decided to add some lead to the keel. Since the draught is already 7 feet, it had to go on the side somewhere, as low as practical. So the idea was born to add 2 half bulbs to it. After some googling and a hefty streadsheet a mould was made.

 
           
 

 
           
  The mould went to Whangarei and 2 pieces of lead came back a week later. They were bolted on and faired in.  
           
   
 

 
           
  They were mounted as far forward as possible, since the bow always was a bit up. We have just gone back into the water. The boat is now straight on its waterline, about 20mm lower. It feels more stable already walking around, and according to the rigger, who had to go to the top of the mast, it did not feel "like a cork" anymore. Once the sails are back we will try it out in real life!  
           
  We had our seatrial and it was a big success. Instead of having to reef at 15 knots going upwind, we now sailed in 20 knots with the full sails on. Also the speed going upwind increased, probably because we sailed more upright. So it has been worth the money and effort!  
           
    January 2013      
           
  After 26000Nm and 5 years we hauled out in Opua to inspect the bottom and if possible to permanently fix the leaking. The feeling was that it came from the keel area, even though inside the boat it came in at the front. This is what we found.  
           
 

 
           
  In the late 1990's the keel had been separated from the hull to inspect the keelbolts. When the keel was joined again, a flexible sealant was used to make sure it was watertight again. This was all fine, until we started sailing the boat hard. Of the 26000Nm we sailed about 10000 were hard on the wind. This made that the keel started moving slightly which sucked in a bit of water with every wave. Normally the leaking would stop after a few weeks at anchor. When we hauled the boat and pushed against the keel while hanging in the travel lift, water would push out of the seam where is was joined.

The top of the keel and part of the bottom of the boat were grinded down to bare wood. The seam was routed out to about 20mm deep and 10mm wide. This was filled with epoxy with high density filler, so the keel was now supported on both sides. Then the whole join was heavily glassed in and faired. All keelbolts were services and tightened.

 
           
 

 
           
  Parts of the bottom got sanded down and faired. Any irregular areas got the same treatment. Next all bare areas got a fresh layer of CopperCoat, including the waterline, which was getting a bit thin after cleaning it often in the tropics.  
           
   
           
 

 
           
  Ready to go into the water again. The green areas is existing CopperCoat, the brown is fresh. The propeller was serviced, the cutlass bearing replaced and a few zincs.

The bilge is completely dry now. The keel can't move anymore. Ready for the next adventure......