In this episode of Sailing A B Sea we hook into rebuilding the engine and we reveal our new look dinghy. Rebuilding the engine didn't take as long as we thought it would however the new look dinghy took way too long.

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Closed Captions (CC):

It's now time for this big beast of a tool to
come into play this is a torque wrench that Aydin

has lent us and these are the instructions that
Aydin's printed out for us and the bolts have to be

tightened down in a specific sequence
so that one first that one second

and you go around all the boats once to
this setting on the on the torque wrench

then you go around the bolts again
in sequence with the second setting

One of the things that we promised ourselves we
were going to do once we got to Turkey was to

really give some TLC to our dinghy it's
obviously a very important piece of our

day-to-day living equipment it's our car, it
brings our groceries home and it gets us from

our anchorage to wherever the nearest town is and
over the years that it's been used so far the uv

damage to a particular part of the rubber that
goes all the way around the outside of the dinghy

uh is is blatantly obvious plus the fact
that cost of getting a new cover for it

in comparison to the cost of a replacement
dinghy well it just makes economic sense so

our friend recommended that we use the guy in the
marina here and apparently his work is excellent

and his prices are not too bad considering it's
a marina price. We've also got the advantage that

we have a ton of Sunbrella material that was
left over from the original owner of the boat

and they are kind of shades that go around the
back or privacy screens if you like. In the two

and a half years we've been on the boat we've
never used them they were just sitting in a

locker and every time we wanted to do any work
they were just another thing to take out of the

locker and put back into the locker so we thought
you know we'll supply the Sunbrella material which

will bring our costs down and all we've got to
do is basically pay for the few materials that

the guy is going to supply such as velcro, elastic,
plastic zips and a few other bits and pieces what

we're getting the guy to do is to create some
chaps to go all around the outside of the dinghy

which we'll cover there there there there there
there and there there will be velcroed to the

inside of the dinghy there and then on the outside
of the dinghy underneath that particular piece of

rubber that runs along the outside which has been
severely damaged by the uv light there it will be

attached there by a an elasticated piece of
material that will run around the outside

Also while we're on the subject of covers we're going
to get a cover for our outboard engine and we've

asked the guy also to incorporate the lifting
strap into the cover so that we don't have to mess

around with the stupid thing that we've got at
the moment which is kind of like a Chinese jigsaw

puzzle with a piece missing, it's just impossible
to get back on so that's this thing the cover

for that and the lifting strap onto the outboard
engine. Onto our seat, our seat has further worst

in the uv degradation stakes um the material is
just absolutely useless, I'll zoom in on that for

you and you can see the absolute awful state that
it's in, that bit there is probably all that's left

of the seat material. For some reason known only
to the designers of these seat bags at Zodiac they

made all the zips out of metal instead of
plastic and of course in a saltwater environment

it doesn't make any sense they corrode,you can't
open them and of course they start to fall apart

so we're getting a new bag made, a new seat made, so
this thing should look schmick as schmick can be

by the time we have finished. Well I've just come
down to the shop where the guys are putting the

canvas together for the chaps and everything else
for the dinghy and it's coming on fairly good I

just hope they can get it all done by the end of
the day. I will go and check in with them in the office

now. It's taken a long time to get the dinghy
finally covered with the chaps, an engine cover

made and a new seat and seat bag made mainly
because the guys at Technical Services were

I don't know quite slow at doing what they were
doing. We did originally supply them with all of

the blue Sunbrella because we had a lot of it just
hanging around the boat, they have done a great job

putting all of that together and uh fitting around
the various handles and parts of the dinghy that

need to be exposed they've got some nice leather
here. It looks pretty good, they've done a great

job of making it fit nicely. The seat cushion
however is a little bit of a disappointment

we asked them to make this hanging bag underneath
where we can stow things and they've made the bag

to fit obviously inside the dinghy itself but then
they've made the seat cover almost the same size

as the bag so it's actually short by that much
so disappointing. Now you could say well send it

back to them and ask them to make another one but
the time it's taken to get here and I'm talking

months it's just like I've given up now I'm not
I'm not going to get involved. So the seat

is a bit of a disappointment. Moving on to the
engine cover, they took a long time getting this

all sorted out and we did initially ask them to
include sewn in a proper lifting strap so that the

we can lift the engine off the back of the dinghy
using the davits on the back end of A B Sea and they

hummed and hah-ed and said because of the shape of
the engine it wasn't possible to put a lifting

strap on this engine which is an absolute fallacy
because we've had a lifting strap on the engine

and I took our lifting strap to them and said
look you know can you put this on the engine

and make it work somehow and then stitch it into
the cover? Well I don't think they've even made an

attempt at doing that so again disappointing and
after months and months I'm just giving up. They

still have the lifting strap so I've got to walk
over there and pick that up at some point and just

attempt to put it on myself. It looks great and it
offers great protection to a very expensive dinghy

Let's talk price. Remembering we supplied all of
this Sunbrella which is quite an expensive item

they only supplied this uh faux leather
material and the stitching obviously and the

elasticated bits that go around the outside
to keep it stuck onto the um onto the dinghy

They originally asked for 650 euros
which is pretty steep considering

we supplied most of the materials.
Eventually I bargained him down to

580 euros which I thought was still a steep
price but he wouldn't budge any further from that

and so when that converted to lira it was 5000
lira exactly and when the guy came for payment

the other day I said well you know you still
haven't put the lifting strap on it he said well

I'll knock 200 lira off for you, so final
cost was 4800 lira. Was it worth it? Yes

protecting the very expensive dinghy just had
to be done and these are the easiest guys to

access. Was it like pulling teeth? Yes
very very slow to react and um not

not uh not doing exactly what was like asked
in the first place. Would I recommend them?

Probably not. Anyway enough of me going on like a
whinging Pom, we've got to get back to the boat

because we've got a box to open. It's day two
of the engine strip down and today's mission

is to clean the engine and the engine bay now
that we've removed all of the top end parts

we've got a lot more access to areas of the engine
that we couldn't get to previously and they are

still coated in the oily soot from when we had the
hole in the exhaust elbow. Kev's going to show me

how we clean off the residue of the gasket from
the the cylinder head. Kev's also going to show

me how he cleans the inside of the bores.

Well it
looks like that comes off quite easy Kev

is it or are you putting a lot of pressure on that? It's not
too bad this this. Okay. Quite good it can be a lot than this

So that's just the residue from the old gasket
that needs to be taken off without scoring at

all the the head itself uh and then as soon as
that's finished we'll come back and show you

how Kev cleans the inside of the bores. That
looks like an odd place to put your cup of tea

so what what is that in there then? It's a little drop
of petrol. Petrol okay so you're just rubbing

that petrol around the inside of the cylinder
the bore right and that just cleans all the um

cleans all the carbon off yep
okay so actually on the top of the

piston I can see there's a lot of gunk in there
what's the what's the plan for getting that out

of there? Once we've cleaned these the tops of the
bores. Yeah. Then we bring the pistons up

Right. And then that stops anything anything
falling down inside the cylinder head. Right

the bores rather, and then it's easier to clean
the pistons. All right now comes the time to

bring the pistons up to the top of the bore. Kev's
going to show us how we do this manually. All right

all you need to do is put a socket on the front
pulley turn until the pistons the two outside

ones should be on top now. Well that's Kev's
surgery procedures over all that's left now is

for me to clean the rest of the engine, clean the
engine bay bilge and then we wait for parts and

as the parts come to us we put the bits and pieces
back on. Meanwhile up in the cockpit I'm once again

using Aannsha's toothbrush to clean up all of the
bolts and everything else that came off the engine

We just received a phone
call from Aydin the mechanic

and he said can you please come to my
workshop, hopefully he's got the gaskets and

if that is the case then we can get the parts
that have been cleaned back to the marina we

can get started on putting the engine back
together. This is our um cylinder head core

and uh these are the exhaust and inlet valves for
the four uh cylinders. Wow oh look at that it's so

so smooth, that's just amazing maybe extra reserve!
Okay so all our gaskets and o-rings. This cylinder...

Oh and we've got the turbo back as well.

Oh that's what a dead turbo looks like

Ooh yes beautiful

Okay. One of the jobs we're getting done at Aydin's
workshop is extracting the heat exchanger unit

from its house here. This is the inside bit and
basically you have salt water and fresh water

crossing paths with each other but never actually
touching each other and that's how you cool the

engine and here are the gaskets or o-rings that
were taken out from the original one they've

probably been for a long time but we've got
replacements for those so we're going to swap them

out for new ones. It's been a full 10 days since
Kev and I dismantled the top half of the engine

and got the parts to Aydin for servicing and
cleaning and today being a Saturday and another

gorgeous day here in Turkey we've got all the
parts back on the boat, today's task of course

is to put the cylinder head back on and
torque it down to the exact specifications

which Aydin kindly printed out for us
so I'm just uh gonna remove some doors again

and the boat is going to be explodeified as we
put everything back together. I removed the doors

for you. Thank you admiral. No worries captain
Meanwhile I'll get on with promoting our video

So Kev's here now and here
we are back in the engine bay

the uh the head is nice and smooth we're
about to put the gasket on and the gasket

can really only go on one way
so you can't really bugger it up

That's it hey that's it, it's in there. Those two little dowels as well as

holding the gasket in place they guide
the head in place now that it's in place

now you can put the tappit rocker assembly
on and start putting the head bolts on

Popping those little bits of metal on
top there of valves is uh something

that Aydin said was very very important to
remember, he was very specific about that

These are the last of the head bolts going in and
Kevin was just saying that there are quite a lot

more head bolts than he's usually worked with it's
probably possibly because it is a turbo engine so

there's a higher compression which means it needs
more bolts to keep everything bolted together

Ah so that's snap - Right that's up
to the first setting we've got now

right which is round about four. Right number
two is opposite yeah that's number two all right

so this is the rocker assembly. That's right

Now all the head bolts are
properly torqued down uh we've put the

rocker assembly on so we're just making sure that
the cup of the push rod is sitting correctly and

um now we need torque down these bolts as well.
We're now at the point where we're going to adjust

the gap to specification on the rocker arms
is that right? Yeah this is the one we're doing

first that's the number one inlet - right - so as
to take it round till it's gone on its stroke

the valve will shut again a little way past
it to take it off the cam and then we'll do

it so all right that's coming down now that's
that valve there now is letting in the fuel

it's coming up, that's about the top of its
stroke a little way past it, that's it all right

So you see there's no gap there we need to adjust
it. Tappit gaps all perfectly at 0.2 millimetre. Now

we're putting the injectors back in and we'll get
the new fuel line on there. This is the water pump

which we're now putting back onto the front
end of the engine.

Kev's now working with the exhaust manifold so we've got the brand new
metal exhaust manifold gasket going into place

and the exhaust manifold complete with
the heat exchanger on the top of it

Okay that's it that's it! yeah drop drop drop drop
the aft end. That's it. Right okay well leave it

there now for a sec then I can move things out the
way to get it in where I want it

That's it.

We just applied a little bit of grease in the groove where the rocker
cover gasket goes to keep the gasket in place

once we invert the rocker cover
and put it back into position

We were waiting for the air intake manifold
gasket to come from Istanbul but Aydin said

we'd be waiting for a long time because
they don't have any in the country so

Aydin just made one for us and we're going to
stick this bad boy on the engine this morning. It's

super fiddly getting in there to get these bolts
into place but the one bolt that's going to be

an absolute pain is this one right here this one
this is where the exhaust comes out of the engine

and that bolt there when everything else is on
here with the turbo the exhaust system on here

getting that nut onto that stud is going to be
super difficult. If you remember at the beginning

of this exercise we found that these fuel return
pipes were very brittle so we've replaced them

however the this pipe is slightly bigger diameter
than the original pipe and so the original quick

clips that were on here just don't fit the pipe
and we couldn't buy any of the right size locally

but we could get these hose clamps.
Now that we're putting the injector

hoses back on we can see why they
use the quick clips rather than

these hose clamps so we've actually had to move
them around to get these injector nuts tightened

up. There you can see one of the original quick
clips compared to the hose clamp. Here comes the

big moment we're about to remount the turbo part
and this is uh challenging to say the least so

I've got the turbo you just guide the pipe. So
we've got the turbo housing bolted back on

and I've just injected a little bit of engine
oil into this hole here because this is the

oil intake feed for the turbo and I've just got my
finger down here and I'm spinning the turbo quite

a few times to get that oil round the bearings
of the turbo so it's got some initial lubrication

when we start the engine up. So this little portion
here is a sensor that senses how much airflow

is being sucked into the engine, that has something
to do with being attached to the fuel system so

it kind of like says oh we're putting more air in
therefore we're going to need more fuel and things

adjust accordingly. Brand new gaskets in between
two all made by our mate Aydin. One thing you

don't want on a job like this is any parts left
over and we have one part left over. Fortunately

it's only a hose clamp and we know exactly where
it's missing from we're just putting that on now

All right here's the big moment we have done
everything we can, we've double checked everything

what we're going to do is we're just going to turn
the engine over without it actually firing up and

that'll basically get some oil pumped around the
system and up to the uh the rocker cover area and

build a bit of oil pressure up, then we're going
to prime and bleed the fuel system to get rid

of any air and then once we fire it up again
she should go like a rocket. Fingers crossed!

Next week on Sailing A B Sea we fire up the
engine for the first time since its rebuild

and we'll also give you breakdown of the costs
involved. We'd like to welcome aboard Clive Willis

who's our latest patron, welcome aboard Clive
it's great to have you with us. Thanks to all of

our patrons, our subscribers and followers, because
you really do help us to keep afloat and to keep

our journey going. We've also updated our website,
it's a lot faster loading and we've got a brand

new shop which has got lots of really great gift
ideas for Christmas. So check it out, the website

address is on the screen right now. So until we see
you next week on Sailing A B Sea, stay safe and healthy