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DIY
Boat Owner 2006-#3
www.diy-boat.com
1-888-658-2628
contents 2006-#3
17
columns
14
Plastic Prejudice:
Using the right plastic
is the key to success in fabrication and
application.
By Patricia Kearns
scUttLeBUtt
17
WOrKSHOP
Epoxy, polyester and vinylester are the
common resins used by do-it-yourself
boat repairers. Knowing when and
where and why of each type is key to
the how to of a successful repair.
By Nick Bailey
iN a CaN
23 DIeseL enGInes
Bleeding Basics:
The correct approach
to purging air from a fuel system after
changing fuel filters or when the fuel
system is cranky.
By Lee Mairs
26
Getting Grounded on Grounds:
Electrical
grounds play an important role with
respect to equipment function and per-
formance.
By John Payne
eLectRIcAL
29
29
etHaNOl
eFFeCtS
There is reason for concern about the
impact of E-10 blend gasoline used in
marine engines.
40
Life Saving Switch:
Install an engine
“kill” switch to ensure that the engine
shuts down if the driver is accidentally
ejected from the boat.
By Steve Auger
PoWeRBoAt RIGGInG
32
PiCture
dish technology
PerFeCt
With today’s satellite
42
QuiCK
potable water
CONNeCt
Installing a modern
55
Rail Protectors:
These easy-to-make
acrylic fabric covers will keep sun,
salt, ice and pollution from damaging
varnished handrails, toerails and other
brightwork.
By Jim Grant
seWInG WItH sAILRIte
you can enjoy high definition picture
quality and hundreds of channels while
underway or on the hook. Here’s what
you need to know to install a satellite
TV system.
By Jim Discher
32
58
Point and Shoot Helmsmanship:
Once
“on the stick” will be enough to convert
even the most conservative helmsper-
son.
By Patricia Kearns
BoAt HAnDLInG
plumbing system is, literally and figu-
ratively, a snap once you’ve cleared the
planning and purchasing hurdles. This
guide will help you navigate the course
of plumbing terms and product avail-
ability issues.
By Sue Canfield
59
Freshwater Flush; Steady on Course;
Working with Non-Skid StarBoard.
DIY PRoJects
50
50
a FaSteNer
Torsion
64 VIeW FRoM tHe steRn
Maintaining An Even Keel:
Though
innate in each boat’s design, some sail-
boat stability shortcomings are correct-
able by shifting ballast and weight.
By
Roger Marshall
Shear
Tension
Departments
3
Events, letters, news, tips, neat products and
more.
Bolts and nuts on all marine engines
are non-stainless steel graded fasten-
ers. If you routinely mess with these
fasteners, you need to know the grad-
ing codes, the proper use of washers,
the why/why not of locknut use, how
to get threaded fasteners tight and the
causes of failure.
By Doug Cohen
PriMer
cURRents
WIN
Sta-Bil Fuel StaBilizer
log onto www.diy-boat.com for:
•DiY Back issues
•DiY eziNe
•1995-2005 editorial index
10 AsK tHe eXPeRts
Gauge Exchange; Help for Flush Odors;
Alwgrip Vs. Imron; Diagnose Engine Miss;
Short Circuiting AC; Why Not Tar; A Case for
Black Oil ; Servicing Fuel Lines; Humming
Chatter; Who to Call for AC Help.
16
tecH tIPs
DiY ON CD-rOM
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or log onto DIY ONLINE at www.diy-boat.com
HOME
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1-888-658-2628
DIY
Boat Owner 2006-3
1
Technical CD-ROM Library
for Boat Owners
1995 – 2007
52 Issues of DIY:
A technical
reference
library for
powerboat-
ers and
sailboaters.
The editorial
archives of
DIY from
1995 to
2007,
organized by
year and issue from cover to cover.
MRT Series
CDs contain articles from past
Building With Starboard
22 Projects and
Fabrication Techniques:
The ideal choice for
replacing wood compo-
nents onboard – won’t
delaminate, rot or splinter
and requires no paint.
$
19.
95
each
each
issues of DIY Boat Owner Magazine
Marine Equipment Installations
Here’s how to choose,
install and operate equip-
ment for your boat includ-
ing: air conditioning and
heating systems, audio
ED
systems, bow thrusters,
UPDAT
davits, lightning protec-
tion, propane systems,
refrigeration, windlasses and more.
ED
UPDAT
$99.95
MRT BOX SET
Plumbing 101
A boat owner’s guide to
the inspection, mainte-
nance, repair, trouble-
shooting and upgrading
of onboard plumbing
systems.
Fiberglass Boat Repair
DIY Mechanic
Gasoline and diesel engine
service. How to maintain,
troubleshoot and repair
outboard engines, stern-
drives and diesel inboards.
How to survey, repair
and prevent cosmetic
and structural damage
in fiberglass hulls, decks
and transoms. Includes
the step-by-step repair
of minor cracks and gouges, large holes,
water-soaked decks, delaminated hulls
and proper installation of hardware.
12 of the MRT
Series in a
custom vinyl
case. Power
version has
Powerboat
Rigging and
Sail version has Sailboat Rigging.
$119.95
(Specify power or sail)
Nautical Necessities
Making the
Electronics
Connection
NEW
AC/DC Electrical Systems
ED
UPDAT
A guide to expanding,
upgrading, surveying and
troublshooting your boat’s
AC and DC electrical
system. All articles follow
ABYC Standards.
From cleaning to fuel filter-
ing to waterproofing charts,
you’ll find ideas and inspi-
ration in this compilation of
tips to do-it-yourself boat
maintenance, repair and
troubleshooting. Divided into 20 categories
to make look up easy.
Painting & Refinishing
Better Boats
The complete guide to
painting and refinishing
hulls, topsides and decks
with marine coatings.
Launch & Haulout
Practical solutions to deck
and cockpit refitting, inte-
rior renovations, rigging
upgrades, space-saving
equipment storage, safety add-ons and
other nifty items to customize your boat.
More than 200 do-
it-yourself projects.
Provides the
information
you need to
consider when
purchasing,
installing,
operating, and
troubleshoot-
ing marine electronics for most any
layout or equipment and budget in
a step-by-step approach.
$19.95
ED
UPDAT
How to prepare your boat
for spring launch and win-
ter storage. Includes lay-up
checklists, maintenance
and lubrication guides,
engine servicing, haulout
guidelines, easy-to-build
storage covers and more.
Sailboat Rigging
A practical guide to deck
layouts, equipment repairs,
performance upgrades, rig
tuning, sail controls and
steering systems.
From gauges to
propellers to steer-
ing systems, here’s
everything you need to
know to maintain and
repair your boat and
NEW
trailer, improve boat
handling and perfor-
mance, and find solutions to common
servicing problems.
Powerboat Rigging
To order call 1-888-658-BOAT or Shop Online at www.diy-boat.com
CONTENTS/
PREVIOUS/
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currents
Edited by Jan Mundy
Big changes at DIY
DIY subscribers will note some changes
with this issue. The big news is that DIY
Boat Owner magazine is now part of the
Boat Owners Association of The United
States, better known throughout the
recreational boating community simply
as BoatU.S.
Headquartered just outside of
Washington, D.C. in Alexandria, VA,
BoatU.S. is an association of 670,000
boat owners and a worldwide consumer
services organization with a 40-year
history of providing many unique and
invaluable services for boat owners.
Having founded this magazine 11 years
ago on the belief that much of the plea-
sure in boating is directly related to your
involvement with and responsibility for
your boat’s safe operation, condition and
maintenance, we came to the realization
that it was time to ensure that this publi-
cation survive for the next generation of
boat owners.
We are certain that our long held
vision to inspire, challenge and empower
readers with the value and satisfaction
of maintaining, servicing, repairing and
restoring their boats will fit right in at
BoatU.S. where members are treated
with a level of customer service that is
legendary in the marine industry.
Of course, change is never without
a few small adjustments. And so, with
this issue, gone are the drilled holes, a
time and labor-intensive task (expense)
loathed by our printer. If you are a DIY
reader who likes to keep every issue in
a binder, the good news is that inexpen-
sive plastic sleeves are available that
will do the job better. For the price of a
Big Mac you can purchase these three-
hole punched plastic edge strip maga-
zine holders for ring binders at Amazon.
com in a package of 12 — enough for
three years worth of DIY Magazine (just
type in, “magazine strips”). These handy
strips allow you to easily slip your issues
into a three-ring binder and best of all,
the magazine pages are much easier to
turn than the old-fashioned way of stick-
ing a three-hole punched magazine into
an inflexible three-ringed metal binder.
We’ve also redesigned our logo to
reflect a more modern design and we’re
planning a few more changes in the
months ahead to make the magazine
more reader friendly.
However, while you may notice a few
changes in style, we can assure you that
the guts of DIY Boat Owner will remain
the same for years as we continue pro-
ducing this magazine with our new col-
leagues who have long been responsible
for producing “BoatU.S. Magazine,” the
largest circulation boating publication in
the world.
Even so, our commitment to you
remains the same. Every facet of DIY
magazine will continue to focus on
being a primary source for repair and
service technology for amateurs as well
as professionals. As our readers know,
DIY is not a magazine of opinions nor
is it a one-way editorial stream. Rather,
the information contained within these
pages is based on accepted marine
industry practices and ABYC standards
and readers can interact with the edito-
rial team via Ask the Experts (“Ask the
Experts” column) or submit boat-tested
tips (“Tech Tips” column) or nifty proj-
ects (“DIY Projects” column).
In short, we urge you to continue on
this journey with us and to share what
we offer with your friends. We are confi-
dent that this change is for the best.
— DIY founders Jan Mundy and Steve Kalman
a Firm Grip
Inexpensive and reusable
bottom cap prevents sliding
action of wooden supports on
slippery decks.
Do it like a Pro
For many years, DIY’s editor has
conducted boat maintenance seminars
at various boat shows. “Four Steps
to a Shiny Hull” (it’s actually five
steps) is one of more popular topics
and, over the years, DIY has helped
countless boat owners restore their
oxidized fiberglass hulls using profes-
sional techniques. It’s not unusual
for attendees to visit DIY’s booth at
later boat shows and present photos
and discuss their success stories. DIY
reader Wayne Brown of Kemptville,
Ontario, emailed us his reaction: “I’m
the guy you coached over the phone
through the gelcoat restoration tech-
niques you demonstrated at the boat
show last year. Just wanted to let you
know, I finally completed the work on
our 1989 Cadorette 280 that has a
powder blue accent stripe and it looks
amazing! It’s everything you promised.
Thanks very much for your skill and
patience.”
Shrinkwrap is one of the
most effective means to
protect boats from the
ravages of weather during
storage periods and is relatively easy
to apply. (For step-by-step installation
instructions refer to the article in DIY
2003-#3 issue.) One drawback is the
2x4 wooden uprights used to support
shrinkwrap covers. These can (and do)
slide on decks and fall over, allowing
water, snow and ice to pool in the
cover. Since shrinkwrap supports up
to 258lb per sq. ft., pooling can be
hazardous, possibly damaging the
cover and the boat.
D r. S h r i n k ’ s ( w w w. d r- s h r i n k .
com) new Non-Skid Bottom Caps
(US$1.98), solve this problem.
Reusable caps slip over the base of
a 2x4 and are constructed exactly as
the company’s End Caps, which fit on
top of support poles to prevent pok-
ing through the wrap, except these
Bottom Caps have non-marring, non-
skid pads on the underside that offer
friction and stability to keep uprights
in place.
Fuel for thought
“How does rising fuel prices affect
your boating activities?” was the
question recently asked on DIY’s
online poll. Of the four choices
listed, 44.7% selected that fuel
prices had no affect with responses
indicating the same usage as last
year; 21.6% reduced their boating
by 50%, 18.9% opted for more
anchoring and less cruising and
14.7% reduced their boating time
by 25%. To enter DIY’s current poll
log onto www.diy-boat.com.
(www.diy-boat.com)
1-888-658-2628
DIY
Boat Owner 2006-3
CONTENTS/
PREVIOUS/
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3
cURRents
Of tee Handles and Oil
Damped Gauges
In the article titled “Diesel Fuel
System Modifications” in DIY
2005-#4 issue, the author, Alan
Donn, states, “the Racor gadget that
integrates the compound gauge into
the cover’s tee handle isn’t recom-
mended because it can’t be isolated
in the event of a physical wipeout.”
In the system he discusses in the
article, does he not recommend using
this tee handle gauge or this type of
gauge in any case? My single engine
boat has the engine serviced by a
dual Racor 75500MAX2 with a built-
in gauge and a generator serviced
by a Racor 500MA2, which doesn’t
have a gauge in the system. I want to
add a gauge to replace the stock tee
handle to monitor the filter in order
to determine the best replacement
time. Does he recommend the tee
handle replacement gauge in my
situation? Also, are my Racor gauges
oil-damped as he recommends?
Paul Weakley via email
alan Donn replies:
T h e g a u g e
available from Racor is built as an
integral part of the cover closure tee
handle assembly. One of the sources
that I researched as I was writing
the article pointed out that in the
event of a physical impact that broke
the gauge or tore the pipe threads
adrift from the connection, there
was no way to isolate the gauge
and restore fuel tight integrity to the
system. This seemed like good worst
case design thinking so I passed the
observation on in my article and put
gauges in the system using a tee
connection with an isolation root
valve (shown in the photos) so that
the gauges could be isolated if nec-
essary. The Racor approach is just to
tap the closure handle for 1/4" pipe
thread and to add the gauge. You
could probably use the Racor acces-
sory as a starting point and add a
close nipple and valve between the
closure and the valve, but then you
get into issues of overhead clearance
and a lot of junk attached to the
closure handle, which is not a very
elegant solution. The ideal system,
of course, is to have a differential
pressure gauge that measures the
pressure drop across the filter and
provides inlet and outlet pressure
sensing taps with isolation valves
and sensing lines to the gauges.
Unfortunately, this arrangement
increases the system complexity
beyond reason. Observation of the
normal running pressure at the filter
outlet (it will probably run at a slight
vacuum, hence the need for a duplex
gauge) should be an easy part of the
safe management of your power
plant’s fuel filtration. Also, periodic
observation of the filter outlet pres-
sure (increasing vacuum) should give
ample warning of the need to change
the filter element. You do need some
indication of filter outlet pressure
and an oil-damped compound pres-
sure/vacuum gauge with 2-1/2" face,
fed through 1/4 ips needle valve, is
perfect for the job.
To determine whether Racor gaug-
es are oil-damped, just look at them.
To achieve the damping effect, the
gauge body is filled with a viscous
medium, usually mineral oil or glyc-
erin. The presence or absence of the
damping fluid is pretty obvious. My
experience with undamped gauges
(a little cheaper) is that the action of
the engine injection pumps precipi-
tates pressure pulsations throughout
the system that cause the undamped
gauges to be in a constant state of
agitation. Though still possible to
eyeball an average reading, it was
obvious that the undamped pul-
sations would soon cause fatigue
failure of the bourdon tube sensing
elements of the gauges. Engineering
knowledge is always expensive to
acquire; the undamped gauges are
now serving as chart weights.
DIY Boat Owner
™
The Marine Maintenance Magazine
™
2006-#3
P Box 22473
.O.
Alexandria, VA 22304
Publisher:
Michael G. Sciulla
Executive Editor:
Elaine Dickinson
Editor:
Jan Mundy
Associate Publisher:
Steve Kalman
Technical Editor:
Patricia Kearns
Circulation:
Susan Clark
Designer & Illustrator:
Joe VanVeenen
Cover:
Photo by Jim Discher.
Contributors:
Steve Auger, Nick Bailey,
Susan Canfield, Tracy Croll, Jim Grant,
Lee Mairs, Roger Marshall, John Payne
DIY Boat Owner™
and
The Marine
Maintenance Magazine™
are registered
trademarks. DIY Boat Owner is published
quarterly. ISSN 1201-5598
©No part of DIY Boat Owner magazine
may be reprinted or used without the
express written consent of the publisher.
All materials contained herein are copy-
righted and all rights reserved.
While all precautions have been taken to
ensure accuracy and safety in the execu-
tion of articles, plans and illustrations
in this magazine, the publisher accepts
no responsibility for accidents, material
losses or injuries resulting from the use
of information supplied in these articles,
plans or illustrations.
Director of Advertising:
Steve Kalman
888/658-BOAT (2628)
Advertising Email: stevek@diy-boat.com
REQUEST A MEDIA KIT ONLINE @
www.diy-boat.com
Subscription Inquiries:
Call 888/658-BOAT (2628) week-
days 8am to 6pm EST or log onto DIY
ONLINE @ www.diy-boat.com
Subscription Rates:
1 year (4 issues)
$25
add $5
Canadian residents
Foreign residents
add $25
Payable in U.S. Funds only
EZINE (web version) 1 year $15
Periodicals postage paid at Alexandria,
VA, and additional mailing offices.
POSTMASTER: Send change of address
to DIY Boat Owner, P Box 22473,
.O.
Alexandria, VA 22304.
PRINTED IN USA
Corrected Silicone
In the DIY 2005-#4 issue article on
recaulking cabin windows, you sug-
gest using Dow Corning 759 glazing
silicone to do the job. I have tried to
get that product without success.
Jacques Charest via email
DiY replies:
This is our error. The
popular glazing silicone is Dow
Corning 795 not 759.
4
DIY
Boat Owner 2006-3
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1-888-658-2628
CONTENTS/
PREVIOUS/
NEXT/
Drain Plug Quiz
Most small runabouts have a drain plug.
Some are threaded into a socket, others
are the common rubber expandable
type. When preparing our cartopper
to launch
for a family
outing I was
chastised
by my sister
for placing
the drain
plug on the
wrong side.
“It always
goes on the
inside,” I
was told.
Plug location depends on
“How else
hull type and location.
do you drain
There ain’t no law!
out the water
when underway?” Trying to be humble,
I retorted: “It only makes sense to have
the plug inserted from the outside so that
hydraulic pressure helps hold it in place.
No one would dare pull the plug while
underway to drain water!” My righteous-
ness soon faded as I realized that I didn’t
truly know the proper placement of a
drain plug. I needed to dig deeper into
this matter so I checked my position with
DIY’s standards keeper, Pat Kearns.
My first surprise: There are no abso-
lutes about drain plug position and nei-
ther the USCG nor any other legislative
body takes a position on the subject of
the “ins or outs” of plug insertion. A
plug can be inserted or removed from
the inside or the outside of the transom,
of course, depending on access to the
drain fitting. The USCG and American
Boat & Yacht Council (ABYC) both do
require that all boats with expandable
type drain plugs have flotation foam so
they don’t actually sink, drain plug or
not. My second surprise: ABYC H-27
standard references the use of drain
plugs but not their placement. The stan-
dard stresses the need for a watertight
attachment to the hull and that the fit-
ting be “constructed to prevent the plug
body from loosening when the plug is
inserted or loosened for draining” and
that “expandable type plugs shall be
adjusted and designed to prevent inad-
vertent disassembly.”
Plug openings are always below
the waterline. If you remove a plug
when underway to dewater boarding
seas (or leaks), the boat automati-
cally self-bails as long as it’s moving
through the water. This is common
procedure with small sailboats and
RIBs that don’t have a true bilge. On a
runabout there’s the added risk of not
fully seating the plug when reinserting.
The pressure of water slapping against
a hull from the outside could push in
a loose plug (inserted from the inside
of the boat) and the boat could be
flooded. Surprise number 3: There are
no U.S. requirements for recreational
boaters to have pumps or any other
kind of “dewatering” device such as a
bailer. Nope. It’s true. Really, it is. On
the other hand, boaters in neighboring
Canadian waters must carry a bailing
device or a bilge pump, a requirement
that varies depending on the size of the
boat. Bailers can be had off the shelf
in a marine supply store or made by
cutting off the spout top of a plastic
jug. In any case, bailing a small boat of
accumulated water is far less risky or
complicated than pulling the plug.
Of course, this discussion is irrelevant
for larger boats that typically have drain
plugs that thread into a fitting and tight-
ened with a wrench. So, what’s the right
or wrong of inserting the drain plug? You
tell me. If you have a runabout with a
below-the waterline drain plug, send me
your experience via an email to tech@
diy-boat.com
— Jan Mundy
Outboard 100 Years Young
By the early 20th century, rowing (or paddling) and sail were still the primary
means of propelling a boat. Cameron Waterman, a Michigan lawyer, was the first
inventor to successfully market a portable gasoline engine to propel rowboats and
sold the first 15 Waterman Porto outboards in 1906. Ole Evinrude joined the
competition to develop small boat engines in 1909 and his 62lb (28kg), 2 hp
single cylinder engine sold for US$62. A year later, Evinrude sold 1,000 engines
and outboard power was off and running.
— ABYC
CONTENTS/
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DIY
Boat Owner 2006-3
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