GALLEY PUMP REBUILD

Since the galley pump had to be removed for the "under galley clean up project", I decided to re-build the galley pump.  The pump is a Whale Gusher Galley Mk 3.  The re-build kit is readily available for the pump.  I purchased mine from Defender.com.

The pump is held together with a series of screws on either side of the pump.  The screws were removed and the pump disassembled.  From there, all of the rubber components to be replaced were removed.  Here is a picture of the disassembled pump.

Then the pump was put back together with all of the new parts supplied in the re-build kit.  First, the pump arm assembly was put together.

Then one pump cover was re-installed.

Then the intake and outtake valves re-assembled.

The intake and outtake valves were installed to the pump housing and the pump spring installed.

And the other side of the pump housing screwed into place.

UNDER THE GALLEY

I began replacing rotten pieces under the galley today.  I tackled the lower shelf first.  A new shelf was cut out of marine grade plywood using the old shelf as a template.  This proved quite effective as I was able to not only get the shape of the plywood exact, but also able to pre-drill screw holes that matched the old holes for attachment of the shelf to the hull.

The original shelf attached to the hull with a series of screws along one edge of the shelf while one end of the shelf was attached to a cleat mounted to a bulk head.  The cleat was not attached well and had rotted out.  I decided to attach the shelf to two new cleats made of star board so that the cleats would not rot out again.  I also located the cleats in a different location so that there was more support for the shelf compared to the original support.

First, I temporarily positioned the shelf into its intended position and marked the top edge of the shelf on the adjacent fiberglass.

I then installed two cleats below this line by a distance of the thickness of the shelf.

The shelf was then fastened to the hull and the cleats.

Then it was on to the top shelf.  The top shelf was in reasonably good condition, although very dirty from years of use.  The support cleats were not in great conditions, so I decided to replace them.  Two new cleats were fabricated out of starboard and fastened to the adjacent bulk heads.

And then the shelf installed and screwed to the cleats.

Then everything was taken apart.  I will next be priming this entire area (fiberglass and shelves) with Interprotect 2000e and then finish coating the area with a coat of paint.

RUDDER LAY-UP - SIDE 1

Over the last week, the first side of the rudder was laid up.  The rudder was first laid out on a sturdy working table.  Since the majority of the rudder had been cut away, there was quite a bit of flex in what was left behind.  So the first step was to make sure the rudder was straight.  A string line was set up on either side of the rudder and the leading and trailering edges shimmed until both were straight.

Then it was on to putting everything together.  Working off of the existing inner core, several layers of glass were laid to provide a relatively level contoured surface for new balsa core to rest into.  I'm using vinylester resin for the layup.  The balsa was laid into the glass and resin.  The voids between the balsa and adjacent surfaces were filled with Mar-Glass.  Then several (five, I think) layers of biaxial fiberglass cloth were layed over the balsa.  All of these parts and pieces were cut and dry fit prior to the lay up to get the profile close to the desired final profile of the rudder.

Once the lay-up was complete, I put together a make-shift vacuum bag system.  This consisted of, first, a layer of wax paper.  Then a layer of terry cloth towels to ensure air flow across the rudder.  On top of that, a layer of plastic was laid with the edges taped to the perimeter of the rudder.  Then a vacuum / vacuum hose was cut and taped into the plastic.  The vacuum was activated and run until the resin had begun to set.

The vacuum bag system was removed the next day, after the resin had cured out.

The finished surface will be ground down and faired out after I have laid up the other side of the rudder. Laying up the other side of the rudder will be the next step in the process.