Assembly

2014 is the year of the boat. After the many delays this year she MUST sail. It will be a very serious loss of face if Martin goes to Pandan Island for Christmas with anything else than Magayon.

January 25-29, 2014: So finally we got the port hull off the trailer and aligned the hulls using some sophisticated Bosch laser leveling tool. We also cleared up the garage for assembly. From now on progress should be fast. The trailer went back to Los Banos and is now parked in our garden, ruining the grass. We need a better solution for that. Walter recommended Ludring, his carpenter, for making the fittings for crossbeam locating blocks. And he is actually really good with woodwork. So finally we have a good carpenter to help.

Building Magayon II

Hulls aligned and center cross beam placed on the hulls.

 

Making the locating blocks for the center cross beam

Measuring out the locating blocks is a tedious job and it took me a while to figure out how to do it accurately. Each block has to be custom made. Because I only ordered the hulls and not the cross beams from Junction Boatyard the locating blocks were also still missing at the hulls. For the locating blocks we bought some Yakal wood, a hardwood that is used for the keel of Bangkas since it can be submerged in water without rotting. Junction Boatyard had provided the wood for the latching pads but it still needed to be worked in shape. 

Building Magayon Building Magayon

 Fitting the parts for the locating blocks and the lashing pads

Building Magayon Building Magayon

Locating block and raw lashing pad assembled, crossbeam lashed down (with wrong rope)  

 

February 8-9, 2014: One more trip with the trailer to bring the cockpit and a few other parts from Los Banos to Talisay. Not much work on the boat because Gerald and Lanke joined and we did a trip to crater island, the first since 1996. We left at 6:00 in the morning and had a fantastic boat ride with photogenic early morning lighting. Later in the morning four propeller airplanes, maybe from Lipa City airport, were flying formation maneuvers over Lake Taal. Thoughts about WW2 air battles in the sky above the Philippine and Corregidor.

Taal February 2014 Taal February 2014

 

Crater Island (left), View into the crater (right) 

March 2, 2014: Matthias was visiting the Philippines again and came sailing to Lake Taal. He had a look at Magayon and got quite excited, he happily offered to be crew next time he comes. He also acknowledged  that the music came from the cockpit speakers and not from a "get to blaster", and said he was impressed. Fitted the latching pads for the center crossbeam and designed and fitted counter boards inside. Glued them in place with help of Mavic.

March 8-9, 2014: Finished the locating Blocks for the center cross beam and the stopping pads on the crossbeam itself and attached the clamps at both ends of the beam. Removed the latching pads and sealed the holes and the counter boards inside. Then re-attached the latching pads and tied done the cross beam for the first time. Looks good.

The next step was to fit the cockpit. The big question: will it all fit together? 

Kata and Mavic and a set of ropes to secure the cockpit in several intermediate positions helped to lift the cockpit in place and temporarily hold it using the aft cross beam. Looked good, all parts seem to be of the right dimension. I then made a frame that supports the cockpit in the back and holds it at the right height so that working on the aft crossbeam locating blocks could be done without the danger of the cockpit falling down. 

2014-03-09 10.13.01 Building Magayon

Cockpit in place (left); Kata doing the first "Stress Test" of the cockpit (right).

 

Building Magayon Building Magayon

 Using the bow crossbeam to secure the cockpit while working on it (left); Support of the cockpit back while working on the aft crossbeam fittings (right).

The next step was to center the cockpit and cut the notch in the center for the strip in the center of the cross bean. For this I had to take the cockpit off the center crossbeam again, to hold it at the right height I used the bow cross beam placed across the cabins and some lace which secured it sufficiently to work on it with power tools. 

January-March: I am getting an increasing number of Visitors every time when I am working on the boart. On March 2 Ritch was the first visitor who recognized what we are building: "That's a Wharram, " he said, "from down there it looked like a Sharpie..." He turned out to be from the Philippine Boatbuilder Group and gave me some tips about events, plywood and epoxy.  

Status as of March 9, 2014

Building Magayon

Figure above: Center crossbeam attached, aft cross beam temporarily placed and cockpit held in place and supported by a frame underneath. Front crossbeam is just placed loosely to get an impression. 

 


A working holiday, Easter 2014

The Year of the Boat. And yes, we are going to sail to Pandan Island this year!!!

Yes, Martin decided to take shortcuts and use the techniques used by local traditional boat builders to safe time so that this year we can actually make it to Pandan.

INO Myanmar 2013-I INO

Outrigger attachment in Lombok (left); Connection between engine and propeller shaft in Myanmar (center); Throttle control with fishing line (right)

 

"Joke lang". We, Martin, Mavic and Kata, spent the Easter week at Walter's to do some serious work on Magayon 2. Originally Miriam wanted to join too and help but she was busy directing her own film in Cebu, so we were missing her always enthusiastic help.

Here is a list of accomplishments of 8 days of work with several shopping and dining trip interruptions:

  1. Port rudder mounted (starboard rudder was already attached).
  2. Tillers fitted and raw tiller connecting rod made.
  3. Mavic made the curtains and the cover for the bilge pump hoses.
  4. All crossbeam locating blocks and lashing pads fitted and mounted. This took an awful lot of time. Despite me ordering the hulls from Junction Boatyard "according to the plans" they did not fit lashing pads and only provided the loose parts, most of them in raw form. They also did not fit the hulls with the reinforcement boards inside, which added a lot of additional work, and was a tough job, in particular for the bow cross beam where the inside could only be assessed through the small hole in the bow bulkhead. It basically took two and a half days for each crossbeam.
  5. Coated the starboard cabin floor with anti slip deck paint (port cabin was already done).
  6. Water proved the solar powered vents with Sikaflex.
  7. Fitted blocks at the cross beams that prevent the cockpit from moving sideways.
  8. Fitted the canvas seat fastener bar plus the reinforcement bar inside the cabin (again, the latter should have been done by Junction Boatyard)
  9. Made and fitted the four bars at the sides of the cockpits that prevent the cockpit sides from bending towards the hulls.
  10. Fitted the second winch. For this we bought the most expensive screws ever, stainless, made in Ohio, sold by a hardware store in Talisay for 120 Pesos (US$ 3) each, excluding the nuts, which were another dollar each.
  11. Fitted luggage nettings in the port hull and in the center section of the starboard hull (the nets in the front section were fitted by Miriam before).
  12. Bought hardwood for the aft net fasteners, outboard motor bracket and tiller connecting rod. It is very difficult to buy proper hardwood in the Philippines. New wood is just not available. Some shops have "second hand" hardwood of which sections can be re-used. A result of uncontrolled deforestation.
  13. Made the cover for the starboard hull electrical connector board cabinet.
  14. Finished kitchen table / foot hole cover of the starboard hull.
  15. Started laying out the rig: Sheets, halyards....
  16. Ludring, the carpenter of Walter, started making the gaff and some other small parts that are still missing.

Cabin interiors - finished, finally. 


 

Some pictures

Building Magayon 2 Building Magayon 2

Figures above: Canvas seat fastener and bars that prevent cockpit side from bending  

 

Building Magayon 2 Building Magayon 2

Figures above: Curtain closed (left) and open (rigth), kitchen table at the side of the cabin, it can be used to cover the foot hole to provide an additional sleeping area. 

 

 

Building Magayon 2 Building Magayon 2

 Figures above: Nettings for luggage in the starboard hull

 

Building Magayon 2 Building Magayon 2

Building Magayon 2 Building Magayon 2

 Figures above: Locating blocks for for aft cross beam (top left), locating lock and lashing pad, still needing finish (top right); glueing in stopping blocks in crossbeam to lock the hulls sideways (bottom left); bow cross beam lying on fitted locating block (bottom left). The addition at the center of the bow crossbeam is for the anchor rope. 

 

Building Magayon

Figure above: Status as of April 20, 2014 - All crossbeams and cockpit mounted. Canvas seat fasteners fitted but removed again for final finish and waiting for the canvas seats. Trampoline is ordered.

 

It was extremely hot over Easter, approaching the hottest season in the Philippines. Drink consumption was half liter per hour.

Oh yes, before I forget mentioning it: The Wharram plans are amazing. You follow them and when you assemble the boat using all the different parts made, everything fits and is off specification only by millimeters. 

Progress after Easter

17-18 May 2014

A very hot weekend with Kata, the reset of the family was busy. May is usually the hottest month in Laguna, productivity was consequently very low. I managed to desing and make the outboard motor bracket (using an 8hp Yamaha motor borrowed from Matty), and cut some wood for other purposes. And I finally managed to fix the broken wheel of the Opti trailer. The outboard bracket needs some more finish, maybe another hour and then only the  gaff still needs to be built. All other parts are done. Consequently the moods were flying high on the way back. 

Taal May 2014

Magayon as left on May 18.

 

23-24 May - Frustration

A disaster weekend. When I started working on the boat on Saturday the carpender came and brought back three parts we had agreed on him doing. One part was all right, the other two were made from the wrong wood (softwood instad of hardwood) and the third was completely screwed up. It was the tiller connection bar, I had spent half day preparing it, glewing different pices of wood together. They just needed trimming to the reight width. The carpender had left the width but cut the length rendering the part unusable. Frustration in its highest form, I spent half a day, gave clear instructions and then the whole preparatory work was just runined by two saw cuts at the wrong place.

Fed up with local help. Back to working alone.

 

7-8 June - Trampolines

Got the trampolin and the canvas seats I had ordered from GrainPro delivered and managed to pay Tess for it in Myanmar. When back from the trip the goods were already delivered, Mavic had bought some more milled fiberglass, so lots of work waiting to be done.

Mavic and Kata helped fitting the seats. Teamwork, me crawling underneath to fit the screws  in the wooden bars that attach the canvas seats to the hulls, Kata inside the hull fitting the washers and nuts and Mavic checking on in the cockpit for even tightness of the canvass seats across the length, a pretty tough job at 40 degrees heat inside the boat shed. I also did some more work on the outboard bracket and re-built the tiller connection rod the carpender had ruined two weekends before.

Magayon May 2014

Trampolin and Canvas Seats fitted, raw tiller connection rod provisionally mounted.

 

Magayon II, May 2014Magayon II, May 2014

Kata testing the trampolin (left) and happy that she survived it (right).

The mood was obviously a lot better than two weeks ago.

When arriving at home I put together the hopefully last order to SVB for little things that are still missing and two outboard motor tanks that fit the space in the cockpit.

 

June 21-22, lots of small things make a big one too

This weekend I went with no particular plan because from Saturday to Sunday night (3:00 - 5:00) Germany was playing Ghana in the Worldcup, an exciting game we watched in the German Club in Manila (2:2 draw). I assumed that I would not get  a lot done on the boat this weekend. Nevertheless we made good progress:

  1. Rocks off: Finally connected the starboard hull electrically with the port hull. Main power plus audio. From now on stereo sound fills the boatshed when I work on it.
  2. Installed the charger and electrics for the UHF radio.
  3. Got stainless steel angles to mount the outboard bracket to the cockpit made and mounted them. Tested the bracket. Made epoxy fillets for all the screw connections.
  4. Designed a shelf for the aft cabin bit of the starboard hull for the kitchen wear. Since the cabin is much wider than the opening, and the shelf needs to be removable to assess the aft compartment and service the water tank hoses, the shelf needs to be collabsible so that it can be removed and taken out. I came up with one that consists of two parts which hinge around a pivot point.
  5. Fine tuned the tiller connection rod and re-inforced it at the contact points with fiberglass. Same with the tiller ends. 
  6. Got a much better idea for a bathing ladder.

 

Building Magayon 2 Building Magayon 2

Mounted Outboard Motor Bracket: Anticipated running position (left); Raised postion (right)

 

Building Magayon 2 Building Magayon 2

Waterproof conntectors for starboard hull power and audio (left); shorepower connection and audio and power cables at port hull (right)

 

Building Magayon 2Building Magayon 2

 Attempt to make a shelf board for the aft cabin of the starboard hull. It needs to be foldable so that it fits through the manhole but also covers the whole width of the cabin. Looks promising. 

  

Building Magayon 2

Secret messages like this one found all over the boat

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