In addition to the normal sanding, priming and painting, the following major projects were accomplished:
- Needle gunning of the entire Monel sheathed bottom and the bronze keel and rudder to remove layers of built up bottom paint. Needle gunning uses an air driven "gun" with 19 steel needles that attack the paint and loosen it. This method is good for uneven surfaces like the Monel plating.
- Removal of the original Monel propeller shaft. The 1 1/2" shaft was very worn at the cutless bearing and vibration underway had been apparent. A replacement shaft from another boat was obtained and cut down to the proper length. A new flange was procured and fit to the shaft by Enterprise Machine Co. of Chatham.
- Repacking of the internal stuffing box. This required the replacement of six pieces of flax packing, each one carefully rotated 90 degrees from the one before it. This job and the shaft work had to be done under difficult circumstances, as the person doing it has to lay on his side.
- Repair of the foredeck area. The section aft of the scuttle coaming had been wet for many years and some evidence of rot was apparent from below in the survivors compartment. The fiberglass covering was carefully cut away, revealing two layers of riveted 3/8" cedar on top of the deck frames. The affected frames were treated with thin epoxy, then built up flush. Two layers of 3/8 " marine plywood were shaped and glued in with 3M 4200 sealant. The underside of the fiberglass was ground down and the pieces were cemented down with 4200.
- Replacement of two oil filter assemblies with new spin on units. These will make oil filter replacements easier in the future. The fuel filter was changed at this time as well.
- The compass was removed and serviced by Jeff Kauffman of Cape Compass in Falmouth. The lubber lines were repainted and the fluid replaced.
- A 12 volt outlet was added where the bilge pump switches are housed. This feature will allow us to recharge cell phones, plug in an inexpensive spotlight, or anything else 12 volt that can connect with a cigarette lighter adapter.
- A second VHF radio has been installed on the boat.
The all volunteer crew of the CG36500 is extremely grateful to the J.W. Dubis Company of Chatham for providing a suitable work place for us to accomplish these tasks.
In excess of 330 man hours were expended on these tasks between March 31 st and May 17th, 2006.
Funding for this maintenance project came from fundraising efforts, private donations, the Orleans Historical Society and valuable volunteer service.