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Rebuilding Saves Money

Last cruising season while enjoying the warm tantalizing waters of Fiji, you may recall we had some electrical difficulties with our windlass motor and engine starter.  

I had saved the defective windlass motor with thoughts of possibly rebuilding it.  A few weeks ago Jilly alerted me to a cruiser advertisement of a used Lighthouse windlass motor and parts for sale in the Opua area which is about an hour north of Whangerie.  We made contact with Gary Slidell and eventually made a day trip up to Opua to have a closer look at the used motor.  

We met with Gary and I examined the motor which had been taken apart.  The magnets were still attached and in place inside the cylindrical motor housing.  The end caps and the brush assembly although covered in carbon dust all appeared to be in serviceable condition.  The armature, windings and commutator appeared to be in good condition as well.  Gary only wanted $89 USD for the unassembled, used motor.  He, in fact, sweetened the deal by offering a chain gypsy and a guarantee that if the motor didn’t work once I got it back together, he would provide a full refund.  I figured I had nothing to lose except my time.  

A few days later back in Whangarei, I decided to begin tackling the motor restoration.  One of the long skinny bolts that holds the case together had broken off in one of the end caps.  The first order of business was to get some new bearings, an end cap seal and a new long, skinny case bolt.  Here in Whangarei is a business called Donovans, a place where you can get or order just about anything needed to rebuild electric motors.  This is where I obtained the bearings, seals and some treaded stock and nuts that matched the tread pattern of the damaged end cap.  Next I took the end cap and treaded stock to a local machine shop to have them extract the end bearing, broken machine screw, cut the treaded stock and weld the nuts onto the rods to make new long, skinny case bolts. 

Back at Dazzler I cleaned up the brush assembly, case and other end caps.  Everything was starting to look like a clean motor that might return to life.  The armature and commutator were inspected and found to be in good order.  I did take it to the machine shop to have it turned on a lathe to clean up the surface of the commutator.

Once everything was back from the machine shop it was time to start to get it back together.  First I wanted to give it some fresh paint.  The exterior surfaces were all prepared, primed and finished with a top coat. 

The next day after letting the paint dry, I installed the new bearings and seal and began the reassembly process.  Both end cap joints were slathered with silicone sealant to help keep out water.  Everything looked proper and I didn’t have any parts left over which is always a bonus. The Kevlar coating was then replaced with the aid of a good contact cement.  Now it was time to apply a 12 volt power source and see what happens.  Jilly provided the drum roll and Bam!  It worked both forward and reverse.  Dazzler once again has a replacement windlass motor.  

There are those that might say why not just buy a new motor?  The company address for Lighthouse Manufacturing is in Riverside, California.  The cost of a new replacement motor is approximately $1,200 USD and then there is the shipping of a very heavy electric motor to New Zealand.  I hate to think what that may cost.  Obviously, if we had no other options we would have ordered a new motor. 

All in the cost of rebuilding this used motor in US dollars.

As you can see a working motor at a fraction of the cost of a new motor and it leaves money left over for the next project.  Sometimes rebuilding something can be worthwhile.  This was the first time I have ever rebuilt an electric motor.  Thank goodness for the internet and the plethora of “how to” videos and other valuable information at your finger tips.  As I have said before, “If it’s already broken or not working, You can’t hurt it any more.”  Besides I had a return refund waiting for me if it didn’t work.  LOL  Trying to fix something not working is something I believe in and have employed many times in fixing other issues on Dazzler.  The worst case scenario would be buying and shipping a new motor from the States.  The best case scenario is we saved some money and I learned a new skill of rebuilding an electric motor.  The satisfaction of a “can do” attitude….Priceless!

By the way, the old motor that had stopped working in Fiji would have required a $650 USD rewind on top of new bearings and new brushes.  This motor is identical to the replacement motor currently on the windlass.  I decided to cannibalize some of the parts and save them for a rainy day down the road.  You never know what can happen in Water World and what is useful until you need it and seashells and coconut husks won’t work.  LOL

Until the next time this old man writes another article, stay healthy my friends with fair winds, following seas. 

Cheers!

Captain Dan

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And Now For Some Good News

Well these are some crazy times we are living in to be sure.  Of course this isn’t going to stop us from continuing our mission to help the children of Fiji. As they say, “Adjust, adapt and overcome.” This is what we are doing so we thought we’d provide everyone with a little update.

First lets start with the good news. Thanks to all of our fabulous contributors we not only met but exceeded our goal of $3500 USD. Thank you Captain Lawnboy for jumping in after our last post and making up the difference with your very generous donation! For books $3500 may not sound like a lot of money but our dollar goes a long way here in New Zealand so that’s actually more like $6000 USD and that my friends will get a lot of great books!

Thanks for all of your help Dave!

Of course in addition to buying them we have our generous book donation partners who stepped up to help. Thanks to Dave at All Marine for coordinating with Irene of Zonta International and the Kokopu Elementary School we picked up close to 700 books a couple of weeks again. Also, Judy Allison of the Lions Club coordinated helped us to acquire another 400-500 books. The community support for this is unreal!

We picked up the first boxes of books from Dave a couple of weeks ago and our first order of business was to get some organization going. To that end we needed to pick up some smaller, more uniform boxes. It’s important for the cruisers who will haul and deliver them to have them in smaller, manageable size boxes that store easily on a boat.

Since Dazzler was still in the yard we took the books we picked up from Dave back to the boatyard and set up a sorting station there. For several hours Jilly went through the books checking for ones with torn or missing pages and organizing them to be boxed. Dan did the boxing and heavy lifting. We filled each box with a variety of books for kids of all ages. In the end we had 12 boxes of books ready to be handed over to the Cruiser Angels who will be the making deliveries.

Of course we don’t have the ability to get them to everyone just yet so we needed a place to store them. Our dear friend Allan Gray at Wynn Fraser Paints offered to store them in a storage area at their store. Thanks Allan!!!

Thanks Judy! Love the great journals and other books!

Just this week we picked up 7 more boxes of books from Judy Allison, the District Governor for the New Zealand Lions Club. While the books from the school were fun reading books, the books from the Lions Club included a couple hundred reading journals for teachers to use in addition to a couple hundred other reading books. Looks like we probably have somewhere around 1200-1400 donated books. This was completely unexpected but certainly a blessing.

So what are we doing with your donations? Well, Jilly spent days and days on the computer researching and reading about children’s books. We ordered a couple of hundred brand new books and some large, wall maps of the world. Maps are big for these kids as they like to see where they are in the world.

Since we have tons of great reading books including everything from Charlotte’s Web to Br’er Rabbit (one of Jilly’s favorites), we decided to spend the donated funds on good, educational books including Children’s World Atlases, books on animals and some really great ones that talk about people and cultures across the globe. There’s some science books and other fun learning material on it’s way to us as well AND we still have more money to spend on new books.

We figure by the time we are done we should have somewhere around 2000 books to deliver to the deserving children of Fiji and you are part of this great accomplishment. Thank you!

Of course as we’ve said, given the state of the world at this moment, we have to adjust, adapt and overcome. So what is the current status of delivering to the islands?

Well, honestly all of us cruisers are in a state of suspension right now due to the coronavirus. Borders are closed all over the globe and Fiji is no exception. Right now we are not even sure we will be permitted to sail to Fiji this year. It all depends on when the borders are reopened. For those of you who are not sailors, it’s not just of matter of them opening the border and us taking off. We have weather and seasons to think about.

Being in the southern hemisphere Spring starts at the end of September. With Spring and then Summer comes the potential for cyclones. Cruisers with any sense of sanity don’t sail north between November 1st and the end of April. So, if the borders do not open up for six months or more we may be required to stay in New Zealand until next cruising season. If this is the case then we will find a small storage unit and store the books for the year. We have every intention of delivering these books personally to the children. If the worse case scenario occurred, we could ship them but due to the weight of this number of books it could be a very costly proposition. As much as we’d like to get them over there this year it may have to wait. Obviously the health and safety of everyone involved is our top priority.  

So, at the moment, we are hovering about in a holding pattern. We will keep everyone updated as the days and weeks pass but don’t worry we will get the books to the children one way or another!

In the meantime, stay safe, be healthy and keep smiling!

Cheers,

Jilly & Dan