Reefer Madness part 1

This being Washington and all, you know how we love our reefer.  Whether its Norcold, Cool Blue or Isotherm, we just can’t get enough of that stinky R134A refrigerant and the intoxicating effects of eating food free of mold and salmonella.

DSCN1301

Melissa really exploring the space as we re-insulate our reefer box.

Thus begins a large and critically important project on the long list of large and critically important projects aboard Galapagos.  There was no refrigeration system on the boat when we bought her but it did have a seemingly huge insulated box  (approximately 13 cubic feet).  To our eyes, it seemed very well made and would require only a properly sized refrigeration system to allow us to store all manner frozen foods, cold drinks and fresh vegetables.

The box.  You can see the  lower (freezer ?) door at the bottom

The box. You can see the lower (freezer ?) door at the bottom

If only any boat project were so simple.  A former owner of  Galapagos follows our blog and privately emailed me that the refrigeration system was a constant source of aggravation and expense for him.  He could never get the system to work efficiently.  His suggestion was to gut the entire arrangement and build up a new system.

FullSizeRender (6)

The lower door. While well made, it seems a bit awkward to access.

After looking at various drop in units at the Seattle Boat show, Melissa and I thought perhaps we should buy a nice drawer type unit made by Vitrifrigo. We even drove up to Sure Marine in Seattle to have a look at their systems.

Interestingly when we showed the salesman photos of the existing box, he was impressed and thought it unlikely we could do much better.  He believed a little extra insulation and a good holding plate system would be superior to anything we could buy off the shelf.  That was music to my ears as my vision of a huge freezer/refrigerator was revitalized.  I have mentioned Melissa’s insatiable lust for power in a previous post. A lot of that power goes into keeping food cold and I tend to perseverate on our batteries and their condition.

So now we started in earnest to improve the existing box and install our own cooling unit. At this point, I don’t need to remind you of how much we like doing things ourselves. We never let a little thing like complete ignorance on a subject stop us from forging ahead, making mistakes and figuring this stuff out as we go along.

FullSizeRender (7)

You could climb inside this box.

One of the more highly touted holding plate systems we have looked at is called CoolBlue by Technautics. We have met Rich Boren, The owner, two or three time at the Seattle Boat show, flogging a very efficient holding plate and air cooled compressor.  Every time I’ve met the guy, I came away impressed with him and the product. Reassured by our visit to Sure Marine, I emailed Rich with some photos of our existing box and asked him for advice.

Rich, although busy flying from one boat show to another was quick to reply to our email asking for his opinion on how to proceed.  In short, Rich saw the large size of the box and the freezer door opening at the bottom as being the two biggest problems.  Every time that freezer door was opened, the cold air would spill out and be replaced by warm, moist air.  Besides having to re heat all that air again, the moisture would cause a rapid build up of frost on the plate which would further reduce its efficiency.  His suggestion was to build a new insulated bottom with three or four inches of well sealed  polyisocyanurate insulation and cover it with plastic or fiberglass panels.

So for about a hundred dollars, I bought a sheet of one inch R-Max Insulation, a sheet of FRP panel and a roll of Extreme Temperature Metal Sealing Tape. Along with some adhesive and caulking, I proceeded to create a new, better insulated top loading box. Once committed to the project, my only worry was what the final volume of the box would be.

Cutting the panels.  Use a razor knife to score the back of the panel (the smooth side) and then bend it slowly over an edge. This makes a straight line without a saw and the attendant dust.

Cutting the panels. Use a razor knife to score the back of the panel (the smooth side) and then bend it slowly over an edge. This makes a straight line without a saw and the attendant dust.

Polyisocyanurate insulation has a higher R value than the commonly used extruded polystyrene (R6 vs. R5 per inch) but it does need to be carefully sealed as it will absorb moisture more readily,  The foil tape I used was very heavy duty and has a really tenacious adhesive.  I can see keeping a roll of that aboard for other projects.

Taping any exposed insulation is important.  Check for punctures in the foil backing and cover those too.

Taping any exposed insulation is important. Check for punctures in the foil backing and cover those too.

In order to get some of the larger pieces of insulation through the door, I had to cut one side of the foil and break the insulation in two.  Once inside the box and ready to be glued down I would tape over this exposed insulation.

In order to get some of the larger pieces of insulation through the door, I had to cut one side of the foil and break the insulation in two. Once inside the box and ready to be glued down I would tape over this exposed insulation.

DSCN1294

The back wall of the box has a bit of slope that needed some extra fill. I used the spray foam for this and other small gaps.

 

Once we had four inches of insulation on the bottom, we went around the entire perimeter with another round of tape.

Once we had four inches of insulation on the bottom, we went around the entire perimeter with another round of tape.

It was nice to see the fresh new panels going in. It makes the whole box look brand new.

It was nice to see the fresh new panels going in. It makes the whole box look brand new.

After laying in the new bottom, I started adding insulation to the sides.  At this point I was starting to count cubic inches. Adding an inch of insulation to the side of the box has the affect of reducing the volulme of the box by another third of a cubic foot.  But I knew that if this system was to work efficiently it would be better to add more insulation.  I ended up adding another inch to the two of the sides of the box and using Reflectix on the other two sides.

I added an additional inch to the sides that would be facing the hull and the in the new freezer section.

I added an additional inch to the sides that would be facing the hull and in the new freezer section.

All glassed in. Just need to caulk the edges.

All glassed in. Just need to caulk the edges.

A high contrast shot of the caulked edges.  In person, you can hardly tell the difference in color.

A high contrast shot of the caulked edges. In person, you can hardly tell the difference in color.

In the end, the box has a volume of about five cubic feet and it looks like a million bucks. The new FRP panels totally transformed the interior of the box.  In addition to this main box, we still have  the lower section with the door.  Hopefully this area will remain cool without robbing too much  energy from the refrigeration system.  We think this area will be like a crisper and at about two cubic feet, it represents a pretty sizeable space.

One result of the extra insulation is that the stock holding plate for the Cool Blue system would be slightly too large. The stock plate is also 2.5 inches thick which I worried would steal more volume.  Fortunately Rich Boren will provide a smaller plate that will just fit.  That will be delivered next week.  Stay tuned for the next episode of Reefer Madness.

 

Workshop Makeover: Luxury or Necessity?

Owning a large, complicated machine means you need tools, and a place to work on said large, complicated machine.  This is true for a boat, a house or a car.  In case you missed it the last 25 times, Galapagos has a great workshop area; storage and a proper bench with a vice and lots of hammers for wanging on stuff.

The shop before we even owned Galapagos.  A bit messy but full of potential.

The shop before we even owned Galapagos. A bit messy but full of potential.

I won’t lie, I am proud to have a boat with a workshop. It feels like a luxury that I could never have imagined on our boat. But it is a practical luxury, especially if you intend to live and cruise for extended periods.  Both Melissa and I would far rather repair or build something ourselves than to wait for someone to do it for us. If something is broken, at a minimum I want to beat on it with a hammer for a bit just to make sure it stays broken.

So, while the shop is a great resource on Galapagos, there were some fundamental issues that kept the area from being as useful as we would like.  Firstly, the bench top was hinged which opened to reveal what I think was originally a sail locker. Now, all manner of tools, paints, unguents and rags reside in this large, incoherent space.

The workbench raised to reveal the large storage area.  Lots of room but awkward.

The workbench raised to reveal the large storage area. Lots of room but awkward to access.

You can see the problem here.   If  I’ve just torn apart a winch on the bench top and Melissa needs the paint stored beneath, somebody has to wait or clean up their mess. Of late, there is always some project going on and bits and pieces inevitably are left out.  In the photos you can see a cut out in the Fiberglas front that does give some access to the contents below but even that is an issue since stuff just always seems to be creeping out of that hole. Never the stuff you actually need at the moment though.

So, with a year of using this area under our belts, we had some ideas that we hoped would transform the shop into a more practical work area.  I spend a lot of time here and I wanted a space that I would enjoy for years to come.

While we both are pretty skilled at general carpentry, we realized that this project would require a higher level of competence than either of us could muster.  Fortunately, we met Larry Simonds from KnotEtAl.com when we were slipmates and he was working on a Cal 34.  Larry built a great drop down table for our Cal 34, Moonrise at that time, and he has done other small projects over the years. As a sailor and a woodworker, Larry has an appreciation of the vagaries of boat geometry. Together with his discerning eye for color and woodgrain, he is really a fine furniture maker. Fortunately for us, he likes to hang about the docks and can be plied with beer.  Be sure to check out his site for other examples of his work.

Larry Simonds: Chief, cook and bottle washer of Knot Et Al Woodworking.

Larry doing a little boat yoga

Larry doing a little boat yoga

Armed with our ideas and Larry’s skills, we set about to transform the space.  First on the agenda was to build drawers and tip outs into the space. With drawers, we could access items without having to raise the bench top.  The downside to this approach is that we lost some space but the space we do have is much more usable.  Larry made the drawers as long as possible, almost 22 inches to maximize storage. He also blended the stain to match the existing 40 year old coloring of the surrounding wood.  That’s how he rolls.

DSCN1281

Three slideout drawers with catches plus a beautiful Red Elm top. Organizing is still a work in progress.

Since the hull shape greatly restricts the length of the drawers lower down, Larry decided to steal an idea from another drawer on Galapagos and build tip outs for the bottom.  These are used for storing lighter items and I have already dedicated one to rags and nitrile gloves.

 

 

Tip out drawers at the bottom provide storage of smaller, lighter items.

Tip out drawers at the bottom provide storage of smaller, lighter items.

For the bench, Larry had a piece of Red Elm which is just beautiful.  In fact, I am a little afraid to use it as it is just too pretty. Melissa put a vinyl covering on the old bench and I think that might be a good idea for this one as well.

Too pretty for a workbench

Too pretty for a workbench

Now that I can move into this new space, some hard decisions are in order.  I knew that I would lose some volume for storage but I minimized that fact. Now I want to have all of the tools plus our great collections of screws, nuts, bolts, washers and other boat bits all in the same area.  It simply isn’t possible and some compromises will have to be made.  Melissa will come down and help me think this through.  She can see things that elude me.

So, luxury, necessity or a little of both?

You Speak Your Language, and We’ll Speak Ours

Happy Valentine’s Day, dear readers! Today is the day that lovers everywhere declare their undying devotion by spending money at Hallmark and hurriedly stopping at the Safeway for a box of Brach’s Special Edition Extra Corn Syrup on the way home. People have all kinds of ways to say ‘I love you’. Some people go have a fancy dinner and hope to have fancy sex later. Some people do the jewelry thing. Some expect candle light and a bottle of “Je ne sais quoi” or some other French words I can’t think of right now. But after 33 (I think) years of marital bliss, Mike and I have our own love language. At the Little Cunning Plan house, nothing says ‘I Love You, Baby!’ like a big garbage dumpster in the driveway! We were in for a delightful weekend of property clean up! Woo hoo! I’m a lucky girl!

That’s right, ladies and gentlemen, we’ve been continuing on our quest to ‘make space’ for this life transition by throwing things out. What better way to clear out the work area of that pile of rotting lumber, that stack of plastic pots from plants, the remnants of the pond filtration system? How else would we dispose of the little shed that Andrew built years ago in the ‘Lothlorian’ area (which we call our small forested space)?

Goodbye cute little hut Andrew built in his youth. Goodbye lean-to that used to have firewood stored beneath it. Hello wide open places!

It’s the end of an era of letting Andrew go hog wild with wood, saws, nails and screws. We thoroughly enjoyed his industrious years of building things in this big back yard we have. And we miss the sound of his little hammer and Daddy’s drill, his archery targets, the tin cans with holes punched through them where the arrows hit their marks.  Gone are the days of large siege engines tossing big things across the neighbor’s fence. He was like a medieval warrior, or at least a medieval carpenter. They were built to work, and built to last. But we have our memories, fond and otherwise, and on occasion at the tender age of almost 23 he still lets loose a few arrows out back. But I am running amok down memory lane right now and that’s not the purpose of this post.

What is this day without flowers? Here’s one from the garden today. We have an early spring in the Pacific Northwest.

No this post is a Valentine’s gift to you, readers, because guess what you get to do now? Go ahead. Guess. I’ll wait.

Ok. You don’t know, do you? Your super surprise extra bonus gift of this day, because we love you and all, is to watch this great video of us deploying our life raft in the back yard. That’s right!!! I’ll bet most of you have never seen a life raft deployed, and the rest of you are asking yourselves why we would even consider doing such a thing. This is why: the people at the boat show told us to.

There she blows.

We had this life raft that was born in May 1993 and last serviced in 2005. Now frankly, we figured it was still good as gold considering it had been protected in the sturdy (and unbelievably heavy) case in its secure holder on the back of Galapagos for the last 10 years. No sunlight or water could get to it. I called around to some places that repack life rafts and none of them really wanted anything to do with it. You know the story: “Oh, you need to bring it in and let us look at it and then we can tell you if it’s any good.” But we couldn’t get a bead on how much this ‘service’ would cost us, or whether it would even be worth our time. For all we knew we should just fill it with those plastic balls and rent it out for children’s birthday parties.

It has been in our garage for a year or so now with us not knowing what to do with it. So what the hell. We had nothing to lose. We couldn’t dispose of it the way it was because it was considered hazardous material due to the canister of gas. And we sure weren’t going to try to sell it the way it was. The guys at the boat show selling life rafts were familiar with what we had and said that in its day it was considered a really good life raft. They said we should just set if off and see what we had.   We’ will likely have to buy a new one anyhow, so we just went outside and pulled the painter. And the rest, as they say, is water under the bridge.

It was a ton of fun, and almost like an extra Christmas to open up the ditch bags and see what was inside. There was plenty of loot, and most of it was still good. Get a load of this:

Real loot!

What we have here is a kite for signaling help, a very nice, brand new Swiss Army knife with every possible gizmo on it, still in the box, a brand new compass, a nice signaling mirror, two different fishing kits, waterproof matches (still good), two short wooden paddles, and a sturdy flashlight. We also found a lot of drinking water in pouches that was still perfectly fine, and a nice first aid kit with a number of items that can be used, and a bottle of sea sickness tablets. I guess those are toast by now.

Look, baby! It works! Nothing says ‘Manly man’ like extra filth and a hammer hanging on your pants.

Turns out this is a very nice raft. In fact, it looks like it is just as good as the new ones we looked at, especially considering the chances of our having to even use it. There is a little light inside, and one on the top, and a kit with an extra bulb. There is a sea anchor attached, and it has weighted bags around the bottom to help stabilize it in rough seas.

A nice sea anchor, attached well to the outside of the raft.

And now what? We are hoping that if we take it to the same place that inspected it twice before, DBC up in Victoria, B.C., maybe they can service it again and put it in a different kind of case. If there is a way to salvage this life raft and use it, it would save us about 2000$, minus the cost of servicing and repacking it. If you know a resource for us, please comment. If we’ve killed it by deploying it, oh well. We figured we’d have to buy another one anyhow. There is always the children’s birthday party idea.

For your Valentine’s Amusement, here is the video; 4 minutes or so of me trying to get Mike to move faster so the video won’t be so long. Enjoy  .[vsw id=”DDc4UgYmkPo” source=”youtube” width=”425″ height=”344″ autoplay=”no”]

 

After a long Valentine’s Day of hurking great piles of rotting lumber and remnants of ancient remodeling endeavors, and deploying still-perfectly-good life rafts, our evening goes like this:

Melissa: What’s for dinner, Baby?
Mike: Je ne sais quoi.
Melissa: You know you are irresistible to me when you speak French. Come here and get your Valentine’s gift you handsome devil.
Mike: Ow! Donnez-moi l’Advil, s’il vous plait.

blogliferaft