A Gulf 32 Pilothouse Motor sailor 'The MaryJane'. The 1982 cutter designed by William Garden and built buy Capital Yachts, now defunct, of San Francisco. We are the fourth owners, and we have spent the last few years fixing her up, with plans to cruise the north Pacific waters of BC. Lily found the boat on the internet and I went down to Olympia, Washington and checked her out. The price was right so the project began. Bringing a 1980's boat up to a usable state requires a bit of work, and just where to start sometimes is troublesome. First off was fixing up what the surveyor found wrong...mainly minor stuff. Ground fault plugs for AC, etc.
Haul out at Olympia, Wa. There were quite a few jobs that we tackled the first couple of years...a new lewmar windlass new G4 chain and new rode..200 feet of each plus remodeling the anchor locker door and adding forward scuppers. The original had the deck water run off through the anchor locker. This had caused flooding for the PO when he failed to clean his anchor chain and the miniscule scupper in the locker plugged. I raised the bow area and glassed in the triangle door there and put a hatch in instead. We also installed a Norcold refrigeration unit in the cold box, replaced the defunct Ardic furnace with a new Espar furnace. Removed the Dorado vents and repaired the incipient rot there and replaced with two Vetus vents. Eventually we replaced all the plexiglas windows with custom laminated glass with sliders on the four side windows. We replaced the black water tank and hoses. Re-painted the deck non skid surfaces with two part epoxy paint. We added a new sounder as the original unit calved. Inside, the forward bulkhead interior facing had to be replaced due to the afore mentioned flooding. New woodwork in the saloon ceiling and new LED lighting in the galley. I did a lot of rewiring and fusing. pulled yards of old wire going nowhere out. I replaced the fuel feed hose with type A hose. Added a vetus anti overflow device and new deck pipe. New anti surge device as a backup. Installed an FM antanae. Prior to the new engine install we had installed a larger alternator and replaced the injectors. Put in a new hot water tank. Re built the fuel filter assembly. Replaced the fuel tank sender. Replaced all the taps. Replaced all of the 110 ac plugs with GFIC plugs. The list goes on.

Addition of Bimini and Dodger, and below Lily at the helm leaving Tzoonie Narrows, heading for the Skookumchuk. We took a shortish trip up to the Sechelt Inlet in June of 2014. The first time there with the boat. We had done a kayak journey there a few years earlier camping for a couple of nights. This time going through the Skookumchuk Narrows which is a bit of fun! You must watch the slack carefully as this is a long stretch of turbulent water. going in we reached speeds of 8 knots with the flood just starting. Coming back we aimed for the slack at the end of the ebb but due to a strong NW storm the ebb was held back some and we hit 10 kts heading to the final bend. No way to steer.. had to just go with the flow which luckily spit us out. I thought we were going aground on the rocks for sure. Interestingly when we first sailed into Tzoonie Inlet we met up with some friends who also have a Gulf 32. Totally serendipitous meeting.
2015 I installed a wind generator-the Air Breeze model. This machine is an internally regulated generator which performs well once the threshold wind speed is met. About 8 kph it starts producing amperes related to wind speed. I purchased the mounting hardware kit from a supplier in Florida as I couldn't find the individual components here in Vancouver. I am sure they exist here but locating them was near to impossible. Stainless steel in 316 grade with accessory rubber washers etc. The rest of the tubing and wiring was no issue though and with the swivel base mount that came with the kit I am able to lower the whole apparatus by myself to the dock and remove the generator for maintenance. Wind Gen
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| This shot also shows the solar panel on the back side of the bimini, though hard to see. Spring 2017 at Wallace Island MP. |
We found this Sail-o-mat windvane from a fellow who was upgrading his boat to a larger size. Still in the box unassembled for a fantastic price. We don't really use it much around these parts but it is great when we do. Very easy to set up and adjust. All aircraft grade aluminum, and lightweight. Windvane
Above is a short video of the windvane working away out in the Strait.
The first thing that worked well with the solar panel was the watermaker. 40E The solar puts out around 6 amps at peak and the H2O uses around 4.2 amps per hour so they work well together on sunny days. The katydyn 40E is a little small..putting out only 1.8 gallons per hour. This is adequate for two people but you must operate it each day to avoid falling behind. If you do laundry on the boat we may have to run it longer. It isn't a problem to run it but it is noisy on a small boat so we try to operate it when the engine is running or go for a paddle to avoid extra noise when at anchor. It is good to not have to run for water all the time though.
Now we have two banks with 440 AH in the house and 145 in the start. We have changed most of the lighting to low power draw LED. With the Dometic portable freezer going 24/7 and the fridge going 4 to 5 hours and the watermaker going 4 hours daily we have enough capacity to keep everything happy for a couple of cloudy and windless days. If we are in a motoring mode then no issues. Along with the new battery bank we put in a larger capacity ACR bus to combine all the batteries for charging. As well as larger fuses in the primary and secondary runs.
After our summer trip to the Broughton Island area we have found a few more items to add to our 'recommissioning' list. The first was that the propane stove had to go. I like the simplicity of gas, but not all the accessories and condensation etc. So we have gone diesel for a cook stove. Settling on the simple ceramic top rather than one with an oven. We never used the oven except to store the pan anyway. Now we have one fuel supply only. No exhaust inside, and no condensation plus more storage space both in the galley and in the aft lazarette where the tanks were kept. I chucked the barbecue as well..became such a soot monster for the Bimini. Don't miss it, though have often considered a big external gas powered crab pot, haha but that is just stupid!
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| New Wallas 85dt stove. Control switch on the right runs on diesel. |
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| So long Hiller range circa 1980. |
I fired up the new cookstove last week and it is very nice. Dry heat that draws cabin air. and exhausts out the back. |This makes the stove able to double as a heater on those chilly mornings instead of firing the cabin heater. I installed a separate tank for the stove but plumbed it from the main tank via the polishing pump so filling is easy.
When I installed the H2O maker I plumbed the intake off of the engine intake line, as the boat was in the water and I wasn't pulling it out soon. However as we found during our journey there was a problem with debris and crustaceans taking up residence in the through hull causing restriction to the engine cooling system. The worst that occurred because of this was a broken bolt on the thermostat housing that I caused while sleuthing the first overheating event. The overheating was not damaging as I caught it right away, however it demonstrated to me that I needed to overhaul the through hull fittings and create a separate intake for the watermaker. We decided that if we were to continue with our plans for extended coastal cruising that some more serious refits were required. The engine was nudging me for attention. The powerhouse has never let us down since acquiring MaryJane, but I have done consistent maintenance and have changed out the injectors as well. There is diminished compression though and she complains at high rpms. So as the engine is 35 years old we decided it was time. The end of the summer brought us back down to the lower mainland and up the Fraser River to Shelter Island on September 15, and now she sits on the hard. I got to work right away and by early October the engine was pulled and sold to another boater in need of a working machine. I considered rebuilding the block but in the end figured that was a lot of money to spend for an old engine. The new engine which will also be a Kubota block (Beta 35) arrives in January. Meantimes the engine bed is rebuilt, and new throughhulls installed.
Getting ready for the new Beta 35 install DIY.
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| old V1501 |
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| old beds..3 mounts! |
I then used my small chain block come a long to swing the engine out over the cockpit. The yard forklift then was able to pick it off and place it in the buyers' vehicle. Whole operation took 20 minutes. Set up took a bit longer.
The Gulf 32's Universal 5432 was set up sitting on three mounts. Two at the back and one at the front. The new engine is smaller and lighter with more HP and has four engine mounts and so required significant re-modelling of the engine bed. With the spec sheet in hand I began by building a jig and fixing it to the shaft. I then
mounted a small laser pointer to the shaft to mark the angle for the engine bed. Once that plane was established I fabricated out of plywood a riser which I bedded onto the old stringer. I then laid up the mat and woven roving and painted the works with bilge coat paint. I had to place a 4" spacer onto the shaft and then the flexible coupler to allow the engine to fit onto the new beds. I was able to buy the proper threaded lag bolts from a local supplier and dropped the engine in and lagged it down. The alignment was remarkably easy due to the extensive measuring prior to laying up the risers. I needed to adjust the aft port mount down a quarter inch or so to line up the centered shaft with the engine flange. Final gauge measurement of the marker bolt while turning the shaft through 360 degrees was within a couple thousanths so I was pretty pleased. The final engine run up would be the real test though. The Beta man had thought my prop may be a bit large for the engine so we were still a little concerned with that.
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| new beds made of plywood and fiber-glassed in with mat and stitched woven rovingcloth layed to the shaft angle |
| new paint job |
All the plumbing throughhulls are replaced with up to date valves and fittings and a few new through hull fittings installed as well. The black water holding tank is also pulled and new valves installed for the intake and discharge lines. The bronze through hulls are still good and the New Zealand valves of ultra strong composite mate perfectly. These ball valves replace the 1980's cheap gate valves of molded plastic that have performed perfectly for the past 35 years! Though they are no longer compliant with marine standards, and so for any resale opportunities in the future they had to be upgraded. The original installation with plywood backing plates slapped on with a glob of goop would never pass inspection these days though, and the plywood was rotted through..crumbling off when the bronze nut was freed. Luckily I only had to remove one through hull on the head discharge. I will do some fibreglass repair and install the new hull fitting soon, going with a composite fitting here as well. The original bronze through hulls were installed during the lay up so that they are fully embedded. This made removing the fitting a bit tricky, but on the positive side once drilled out and replaced with composite through hull the entire fitting becomes one with the hull. No uneven expansion and flexing.
www.trudesign.nz
I have now got to the end of January 2018. The holding tank is back in place hooked up to the new valves. New y valve in the head and new anti syphon valve in as well. The head sink drain I replumbed to the through hull that had previously accommodated the knotmeter transducer thus no new hole bored for that. As planned our new engine arrived Jan 31. However on inspection we found some transport damage so I sent it right back to be repaired.
So doing all of the little jobs I can think of, cleaning up wiring and rerouting bilge hoses. Checking all the potential issues that may arise stalling the relaunch at end of March.
So received the engine back again and dropped it in. Neighbor helped to wiggle it through the companionway but otherwise very easy to hoist it in using the boom and chain block. the horizontal come along eased the back and forth while lining it up.
Below is a shot of the filters on the right and the stove fuel tank in the middle with the hot water tank at left. There are two banks of filters. Each bank has a primary and secondary filter and can be switched over while the engine is running should it be required. There is also the engine filter which should remain clean theoretically with all the pre-filtration. Below you see at the top of the picture the main aluminum 330 liter fuel tank. At the bottom is the plastic 10 liter stove fuel tank which will receive fuel via the Walbro transfer pump as needed. To the left is the hot water tank.
Another view of the engine. I added the overflow coolant chamber seen below at the top left as the engine doesn't come with one. $13 at Lordco.
Bottom paint finished. Didn't spend alot of time on the bottom this year, but will definitely have to scrape it all down next time. There was a bit of flaking of the old soft paint which I prepped by sanding down and priming with heavy cuprous primer. Will see how this black aquagard soft ablative works. Cost was about 170 a gallon at the store..later I found some cheaper!! damn 145 oh well I used just over a gallon for two full coats to the hull and a third coat around the high turbulence areas.
Fresh anodes. Not really sure how effective binding the large doubleplate anode to the pintle plate is but that was how the PO had it rigged...they also connected it to the cutlass housing. Don't know why because the housing is isolated from the shaft and prop and there are not noble metals there, so I did not attach the anode there. I have a shaft anode at the distal end of the shaft. Last one lasted two years. The previous keel anode was still complete on the port side but 50% gone on the starboard. I also painted the prop with ablative paint, just for the hell of it. I don't imagine it will stay on for long but will be interested to see.
Cleaned her up a bit and ready now to go in the water tomorrow March 16, 2018.
I am hoping for a straight forward re-immersion and commissioning of the engine. I have a couple of things to work out once tied up at the dock, I need to re-position the transmission lever to give me a push for forward gear. Need to fabricate a small piece to facilitate this. In the meantime will need to remember the opposite action.
Any how, back on the water looking for the wiring issue I see the repair work when they replaced the broken alternator. Instead of taking the alternator off the support and then undoing the leads, which is the normal, because it is very difficult to get your fingers in behind without either moving the alternator or finding someone with really small hands, they just cut the leads and then spliced some old wire they had laying around. As you can see they spliced a chunk of red 14 gauge into the brown yellow lead which according to the manual is supposed to go to the tach sender post. Then on the other lead the blue black wire, they found a bit of staight blue wire and fit it on to the lead. However some how they attached the end connectors on reversed. The exciter lead should have had a spade terminal and the tach should have had a ring terminal. The mechanic after cutting the leads then reversed the ends so that the leads were then reattached at the wrong posts. Well after spending several hours checking continuity on all the leads which entailed deconstructing and accessing and removing and you get the picture, I called the owner of the franchise that sells Betamarine engines and we further sleuthed the issue over the phone. He couldn't figure it out until I described the wire colours and where they were attached to the alternator. Then I too saw the discrepancy.

He sent the spares pack gratis as an apology.
Our spot at the docks at Shelter Island is not prime, being on the inside of the dock in the shallows, and parallel parked in between a couple of cruisers with about 3 feet on either end to maneuver in and out. Wow..coming in the first time there were a couple of folks on the dock who came to my assistance and even then due to a short bit of breeze the back end got swung out and I had to do a 180 degree turn and come back in the other way. This is actually what I wanted as there is only one way in and out so it worked out serendipitously. For us to get out I pretty much have to wait until high slack tide and hope there is no wind. I have about a boat length wide of space before the keel will drag bottom so this makes it a bit more problematic getting in and out. Hopefully a better berth will come up soon.
Back to getting ready for the shake down cruise. Once the weather warms up a bit we will take off for the islands and check all of the stuff out. Not anticipating any major issues, but need to restart the water maker and shake out the sails.
Once in the water again the engine ran smoothly at the dock but I didn't take it to sustained WOT as I wanted some calm water and a few hours on the engine first. After running her down the river and doing the break in routine of fifteen minutes of 1/3 throttle then fifteen of 2/3 throttle I checked all the fittings etc and then ran the engine at 1800 rpm across the strait. Next day after further checks and re torquing the shaft bolts we ran it up to temp and pushed it to the WOT stage to see if we could get the spec rating of 2800 RPM. After a few minutes she was up to 2700 and change. The riser exhaust started to burn off the paint and and stink pretty good but the gear was running smoothly and it appeared that the prop was in the ok range. I was happy and the dealer ok'ed the install. I may replace the prop with a slightly smaller one in the future but for now there is no issue.
I have rearranged the shifter so that the action is like it was before..and changed out the fuel filters. Should have done that before but it slipped under the radar. I have replaced the head pump as well, and so far the new plumbing is all performing as expected. I am now considering how to place a transfer line from the watermaker to the main tank. Manually transferring water in the 6 gallon jug is a pain that I need to avoid.
Update...found that there is enough room for a 50 liter tank in the cubby alongside the watermaker. In the picture below the watermaker is mounted on the bulkhead aft of the filter. The tank is well secured from any movement with struts and straps. The small March transfer pump is attached to the sole in front of the tank..you can see the four bolt heads there. To access the machinery that shares this space requires detaching two hoses from the base of the tank and pulling out the tank. The small March pump came with the watermaker as a lift pump, however I found it was not necessary for that purpose but works quite well to transfer the made water to the bow tank.
In the meantime while our spring departure date approaches I have stripped and recoated the galley floor, put in some brass lifting rings where there used to just be finger holes..keeps so much dust and lost items from falling into the engine well. Put the headsail back up the other day and gave the decks a good scrub down. Pretty much down to little jobs now. Lily busy getting all our gear organised and making provision lists. Cleaning up everything after a winters worth of work she is looking pretty ready.
After taking the engine out for its shakedown we found that the mechanical fuel pump had some difficulty supplying fuel at 100% efficiency. I spent a day at anchor re-configuring the Walbro polishing pump to work as a booster pump. Found that the engine would work fine with the mechanical resident pump but occasionally would starve and stall necessitating the electric assist. I like to keep the Walbro for polishing and transferring fuel and priming after filter changes. It is a good quality pump with built in filter and has a demand chip in the circuit so will operate passively, but I think is overkill for this application. I have a smaller marine grade Airex pump that I will install and wire to the ignition. This is what the Beta folks advise doing in their manual so will comply.
I think the fuel feed problems are likely due to the lower fuel pressures when the tank gets down to half full. Now we should have no issues, and enjoy redundancy as well. I have likely put way too much gear on this little issue but what can I say. After year of operating and having the occasional stoppage even after installing the Airex I finally found the cause or the stoppages after they had gotten nore frequent and after I had done everything I could with the filters. I rechecked all the lines that I had installed and all the factory lines, which is just one that goes from a block on the bell housing to the mechanical lift pump and from that pump to the filter then to the high pressure pump in the engine. There are five clamps on that hose line and one of them had been removed..the one at the input to the mechanical lift pump. These hoses have a protective sheath that goes over the rubber hose and the clamps so you cannot readily inspect the clamps and this clamp was off with the sheath pulled up over it...I scratched my head quite a bit over that. You cannot accidentally knock those clamps off. At any rate once found and repaired the engine no longer hesitates at all.
This year (2019) after finally finding and fixing the air leak, we had also built another watermaker. I, being a sucker for punishment, took on the fabrication and installation of an engine driven 20GPH watermaker. Haha. See the blog entry. So we took off to check out our work. The first iteration needed more work, so we came back and I made some adjustments. Going down the river the second time I hit something with the prop...I noticed a sudden change in sound from the engine...initially thinking maybe something else but kept going anyway, sailing over to Clam bay. I was thinking that I had picked something up..had done that before snagged a submerged chunk of branch that got wedged behind the prop. I fixed that by releasing the shaft from the engine and the piece fell out, so I first wanted to check that possibility. We were heading up the coast so I did not want to go back to the dock unnecessarily so when at anchor I viewed the propellor. Long story short we headed back after a bit of sailing up to Club Jed and back. The perturbing noise didn't occur til the RPM exceeded 1500 so it wasn't too bad, but.. then the watermaker drive broke again so we headed back. I had the boat hauled and pulled the prop --had it to the prop shop where it was tuned up. Meantime I had the watermaker platform beefed up. So now we headed back out to check everything out over ten days in the southern Gulf Islands. Turns out the harmonics that the prop had exhibited at 1100 rpms after the new engine install also disappeared with the prop tune. The WOT produced the engine spec of 2800 RPM and it was beautifully smooth. The new watermaker pump base also held firm and the water production exceeded anticipated volumes. So all good. We are going to head up to the central BC coast waters next spring and hopefully will have all our systems functioning as we want them.


























