Velorum #215
Refit of a 1986 Niagara 35 Encore
Thursday, April 30, 2026
Tides Marine Sail Track
Sunday, April 12, 2026
Mast Wiring Complete
It's finally starting to warm up a bit, although not as much as I'd like but sufficient to get back to work on projects. One of the final projects to tackle before the launch this summer is the mast and although the bones of it are sound, a lot of work needs to be done before it's ready to stand up. All told there are 5 mast projects that need to be completed (or are completed).
- Masthead removal and rebuild - completed: here
- Wiring - this post
- Mast track - Tides marine sail track
- Rigging tang installation
- A good scrubbing
Installing the steaming/foredeck light was pretty straightforward and the mounting holes were a perfect fit with the original fixture (including the genoa guard). The tricolor/anchor was slightly more complicated and I'm glad I pulled and rebuilt the masthead unit last year and hadn't reinstalled it, because I needed to find a slightly different mounting location for the tricolor/anchor (the mast never had a tricolor on top before, just an anchor light).
Thursday, March 12, 2026
It's Been a Minute
I have been working on another project that I wasn't entirely sure I'd get to this year, but finding myself idle after the project mentioned above was finished I decided to go ahead and install the Maxwell RC8-8 windlass with capstan. By install, I really mean get ready to install because there was (and still is) a lot of planning and design work to do before I start cutting holes in the boat. After a lot of thought and careful measurements, I came up with a plan where I could build the entire mounting base for the windlass so when the weather finally does warm up I can essentially drop it in and wire it up.
After a lot of research on other Niagara 35s with windlasses, it was clear that I would need to elevate the windlass up off the deck to be able to meet the correct vertical angle (+/- 6degrees) between the windlass and the bow roller. I could have just glued a few pieces of plywood together, epoxied it up and called it a day, but I wanted something that looked like it belonged there, didn't stub toes too bad, and still allowed me to keep both hawse pipes on deck for an additional rope rode that could be hauled on the capstan.As always I like to incorporate CAD designed parts where I can and the more I thought about it, the more I started thinking of creating a 3d printed mold that would follow the shape of the windlass. Initially, I was going to use the dimensions of the holes from the mounting template that is supplied with the installation manual and create a shape that approximated the windlass base in Autodesk Inventor, but my son (who is much better at Autodesk than I am) reminded me that you can import a scanned image of the template, scale it so the dimensions are correct in Inventor and then build the shape off that. So, that's what I did.
I ended up sizing the inside dimensions of the mold 1/2" larger all around than the actual windlass base and then extruded the shape up 1" to make a mold that I could then use to make an epoxy and 1708 biaxial fabric part that could be machined. Once I was satisfied with the dimensions, I added a bottom layer and sent it off to my 3d printer (Bambu 1PS) to make the mold. About an hour later, I had the mold in hand and went over to the shop to make a sticky mess. Because of the size of the part, I didn't want to fill the entire mold up at once to keep the part from going exothermic and cooking itself, so I did it in 3 separate sessions allowing each layer to partially cure before proceeding with the next. During each layup I added 4 layers of 1708 biaxial cloth along with a healthy dose of West System 404 high density filler. I expect it will be plenty strong and much cheaper than 1" thick G10 plate. Once I finished the layups, I let it cure for a few days before starting the machining. The first step was to round over the top edges so there would be no sharp edges that I would invariably kick and stub my toes once installed. I used my router with a 3/8" radius roundover bit and did it in 2 passes to make sure I didn't get any tearout from trying to remove too much material at once.Next I taped the template onto the routed out part and drilled out the three 3/8" bolt holes so the windlass could attach. For the two big holes, I needed to use a hole saw. Unfortunately, I have been using Lennox hole saws for years and have accumulated at least 12 sizes and a variety of collets over the years, but to my knowledge, they don't make metric so I had to settle on a 4" bit for the motor cutout and 2-7/8" for the chain cutout. They were both about 1mm larger than needed, but shouldn't be a problem.
- The base plate (I have some leftover 1/2" G-10 plate) will be epoxied to the deck to spread the load across more area of the deck.
- It will cover the old hawse pipe hole. I will fill this hole with epoxy and cloth, but since it will be covered I won't have to make it pretty and paint the filled area.
- It will raise the entire assembly up another 1/2" and make the vertical angle to the bow roller more fair.
Wednesday, January 7, 2026
Government Silliness (Warning: Contains Bureaucratic Nonsense)
For six months or so I've been attempting to get Velorum federally documented with the US Coast Guard. It's not a requirement, but I've always documented the larger boats I've owned for a few reasons:
- The boat needs to have the documentation numbers permanently affixed in 2 places and it makes the boat a little easier to identify if stolen.
- You don't need to sticker with state numbers (although you generally still have to pay for the state registration).
- Makes it easier to check into customs when arriving in another country. I currently only have Canada on my radar, but dare to dream!
Our office is in receipt of the Last Will and Testament of xxxxx; however, a will by itself does not transfer property. If the will went through the probate process and an executor or personal representative was appointed by the court, please provide a copy of that document. The document must be certified by an official of the court.
I am not a lawyer and do not play one on TV, so I really had no idea what that even meant. I asked the previous owner's widow and she couldn't find any probate documentation. And just to really stick it to me, the NVDC needed the bill of sale to be notarized as well (why didn't they tell me that after the first submission). At this point I thought I might be reaching a dead end and would have to settle for state registration and give up on federal documentation. Except....
In the last paragraph of the three page Letter of Deficiency there was the following sentence:
Please note if the vessel is state registered or state titled in the name of (Me) you may forgo submitting the above document and submit the state registration to start the chain of title.
So as a last ditch attempt, I contacted the friend (of the deceased owner) who sold me the boat and asked if he could meet me and re-sign the bill of sale and get it notarized. He was more than happy to help and we met up at the Hanover NH town hall on an afternoon in late October and had a notary witness our signing.
The next day, I went to the NH DMV and registered the boat under my name with the bill of sale and paid another fee (~$150). The clerk at the DMV was confused as to why I would want to register a boat with only a few month left in the year when the boat wasn't even in the water. I just told her it was a legal thing and I had to do it. She really didn't care as long as I paid my money and showed identification. I went home and uploaded the notarized bill of sale along with the new NH registration on the NVDC site and hit submit thinking that I had probably wasted close to $500 for something that was never going to happen.
Fast forward to January 5th, 2026 and low and behold, I got a real letter in the mail from the NVDC. Before I opened it, I figured they were just sending me a real letter telling me to stop bothering them and to stop submitting things to them. However, when I opened it, there was just a single page... The Federal Documentation! No explanation, just the actual document. Anyway, it's all just silly that the NVDC allowed a state registration to trump everything else even though it really didn't prove anything other than the fact that I drove to the DMV and paid them money, but I'll take it.
Sunday, December 21, 2025
Odds and Ends
Happy winter solstice! It has been too cold and windy to do much work on the boat over the past few weeks, but I did manage to knock one small project off the list. When I purchased the boat there was no sole in floor of the head. It didn't matter for most of the refit but with the launch date getting closer (next spring/summer) it was time to put in a proper sole.
I only needed a small 16"x21" piece of 3/4" teak and holly marine plywood, but I couldn't find anything that small and the thought of purchasing a full 4x8 sheet for $350 was just not an option. Fortunately, a good friend of mine happens to own a boatyard and had some extra bits lying around from a recent project and gave me a nice chunk that would be perfect.
Since there was a seacock and strainer in that section that would need quick access, I had originally planned on cutting an access hole in the panel, but I ultimately decided to have the whole panel lift out once I found some nice snap latches that would keep the panel in place until I needed access. This ended up saving a ton of time cutting, fitting, and finishing an access panel in the sole and only required me to use a hole saw to cut out the latch mounts. On the other side of the panel would be 2 'lips' that fit underneath the fiberglass so once I un-do the latches the whole panel hinges up.
I cut the panel to size, installed the latches and 'lips' and brought it over the boat for fitting. After a bit of work on the edges to round over the underside of the panel I brought it back to the house where it was warm and started varnishing. 2 coats on the bottom and edges followed up with 10 coats on the top. On the top, I sanded between every coat with 220 grit paper. All told it took me about a week to build up the finish to a silly level of shine (and protection).
So that's about it for this year, but I'm already working on the next and almost the last project. The battery power project where I tie all the systems together so I have a starter battery for the engine and a lithium battery for the house bank that will power all the circuits in the boat. I had a system design in mind, but I decided to hire Owen Murphy from Meridian Marine to vet (and improve) my design. He has been really great to work with and seems to be a happy medium between fully designing and installing a system (lots of money) and helping a DIYer with good design best practices so I can confidently install the system myself. The really cool thing about Owen's business is that he is currently sailing in Fiji on his 34 foot Crealock, but he is very responsive and easy to get a hold of. Stay tuned...
Monday, December 1, 2025
Just in Time for Winter
With the temps in the low 30s and a snowstorm in the forecast tomorrow, I decided it was high time to install new refrigeration! Well, not really; I had been planning it for a while and originally thought I wouldn't get to it until the spring but a few weeks back I decided to put the mast rewiring project off until spring instead.
When I purchased the boat it had an engine driven cold plate system that reportedly worked when the boat was last in the water in 2013, but it probably used the old refrigerant type instead of the new 134A and it just took up so much space in the engine compartment. I just didn't want to deal with engine driven compressors, belts, hoses and a series of unknown 'doodads' that probably did something, but I was not interested in finding out. So I ripped it out when I re-did the engine compartment with the plan of installing an economical electrically driven system.I had a number of systems in mind but finally ended purchasing an Isotherm Compact Classic 2012. It seemed like a good combination of cost, cooling volume, and ease of installation (the system is pre-charged with quick connects). The nice thing about the 12v electric systems is that they can be located in a number of locations as long as there is sufficient air flow to keep them cool. They essentially consist of 3 parts, a compressor that can be remotely mounted, an evaporator plate that lives in the icebox, and a thermostat controller that can be mounted in or outside the icebox. The one caveat of the thermostat is that one side has a temp sensor capillary tube that needs to be mounted on the evaporator plate and the other side has wires that lead back to the compressor.
After scouting a number of locations, I decided that a shelf in the port lazarette behind the icebox would be a good location for the compressor because of its close proximity to the icebox, good airflow, and mostly out of the way location. The only issue with this location is that the shelf is sloped downward toward the side of the boat, so this would have to be leveled (the compressor should be mostly level).I measured a 19 degree angle of slope for the shelf that I planned on mounting the compressor on and decided to put the 3d printer to use by making 2 - 19 degree wedges with holes for 2 bolts on each one to mount to the shelf. I used an extra strong print profile (15% infill and 6 solid layer walls) that should have no trouble holding the 15 or 20lb weight of the compressor. I epoxied a 6"x12" piece of 3/4 inch marine plywood to the blocks and tapped the 1/4" bolts that will mount the assembly to the shelf. Finally, I through bolted the compressor bracket to the assembly and got ready to install.
I'll say up front that this was not a difficult job, but I was worried about installing the evaporator and snaking the copper tubing out of the icebox and aft to the compressor. The tubing is pre-bent in a coil and I couldn't help but think that it would be really easy to kink the tubing if not careful. Additionally, the evaporator plate comes flat and it is longer than the length of the icebox, so it needed to be bent. Fortunately, the kit comes with a bending 'dowel' that you screw down to a piece of plywood and use it as a form to bend the evaporator around at specific locations.
Last week just before Thanksgiving, my son and I decided to tackle the evaporator installation. We carefully carried the bent evaporator up the ladder to the boat and started straightening out the coil once we had it in the cabin. First we fed the tubing into the icebox and led it through the hole (from previous installation). Once through the hole it had to be carefully bent around a corner and through a 1.5 inch hole I had drilled in the bulkhead and fed up to the shelf in the lazarette. This is definitely a 2 person job because the copper tubing is fragile and kinking it would be a very expensive mistake. Once we had the the tubing roughly run to where the compressor would be mounted we carefully slid the rest of the evaporator into the icebox and secured it to the vertical walls with screws that ran through 4 plastic mounts that keep the evaporator off the wall by about 1/2".
Thursday, November 6, 2025
Catching Up
Regular life has gotten in the way of boat work and and as result I'm a bit behind with updates on progress. Last week I finally came to terms with the fact that our garden shed was a mess and I was faced with the prospect of spending $10-15k on having a new one built on site or fixing the rot and rebuilding the existing shed for a fraction of the cost. I chose the cheaper route and fixed the rot.







































