Showing posts with label dismasted. Show all posts
Showing posts with label dismasted. Show all posts

January 14, 2016

vene magazine (finland) - february 2016 issue

Vene (Finland) / February 2016
"SEIKKAILIJAT:  Lapsiperhe purjehtii kovaa ja elää täysillä. Tärkeintä on olla yhdessä."
Teksti Auli Irjala ja Somira Sao / Kuvat Somira Sao

Thank you to Auli Irjala and the editors at Vene (Finland) for supporting our mast replacement project with this story about our family & Anasazi Girl in the upcoming issue of the magazine.  Available in print in Finland on February 3, 2016.

August 27, 2015

dismasted - auckland to puerto williams: part 3

Story/Photos by Somira Sao

Below is another excerpt from my story about Anasazi Girl getting dismasted in March 2014. A shorter version is featured in the September 2015 issue of Yachting World (UK).  First parts of the original story can be read HERE.

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The kids understood that we were safest down below and when conditions were aggressive, it was best to be in the quarter berths.  James was sailing single-handed.  He made all sail changes on deck, examined lines to make sure there was no chafing, checked the condition of sails, lines & hardware, and obsessively checked and re-checked all our systems.  On deck he always stayed clipped in and wore a safety harness with a built in PFD.

All of our senses grow more acute offshore, especially hearing, as we are always listening for good and bad sounds.  Good sounds were his footsteps above us, sails getting dragged to the fore-deck or getting dropped down through the hatch, the winch handle locking in place, the subsequent grinding as the lines are adjusted or tightened, the click of the mast cars working as the main gets reefed or raised, head-sails getting furled or unrolled, and sails getting tightened or eased.  Bad sounds were that of a sail or lines slapping loudly, loud bangs, or complete silence.  By listening carefully and sensing changes in the boat, sails could be correctly adjusted for best performance.

All sail changes at this latitude were difficult, but a gybe always required special mental preparation. Gybes were few and far between, with an average of one gybe every 1000 miles.  First we had to make the ballast adjustment down below. The kids would help us with the system of valves and scoops, which needed to be opened and closed in a specific order. They would watch the bright orange balls inside our sight tubes to let us know when tanks were empty or full.

Then James went through a meticulous process of putting on his “action suit.” Paying attention to the smallest details in his preparation to put on foul-weather gear and safety equipment prevented the possibility of tripping, base-layers getting wet, harness failure, a carabineer not getting properly locked, a head-lamp flying off, or a hood obscuring his vision.  All of these things could cause stress, exhaustion, or mistakes, and we were in the business of taking extra care to avoid all of these possibilities.

Out on deck, James took calculated steps to make sure our gybe was a smooth & quiet transition. Once he stepped out, we prepared for the sound of sails getting reefed, lines getting adjusted and stacked neatly, the slide of the track as the boom shifted to the opposite side of the boat, an “OK” call from above, then sails filling, reef shaken, and lines tightened. Our bodies braced down below for the change in the angle of heel on the boat until sails and ballast were adjusted once again for comfort.

Down below my primary responsibility was keeping the kids safe.  All physical movement was always very controlled. Even for our older children to use the head or move about the cabin required direct supervision.  My eyes were constantly on them and on the instruments, watching for imminent or unexpected changes in wind speed or direction.  If the kids were all asleep and tucked in safely, then James and I could sometimes make a coordinated effort to make a sail change, with me driving the boat down below with the autopilot and him on deck above.

Twice a day, we ran the Yanmar for 1-2 hours to charge the house batteries.  Inside the uninsulated carbon structure, it was always a loud exercise, especially with the engine room doors open for good ventilation and easily accessible for inspection.  During this time, we did all our power-intensive tasks: ran the water-maker,  booted up the computer to update our position, downloaded new weather files and SAT-C (Navtex) warnings, downloaded & backed up image files, and charged the kids’ tablets.  Once this was done, we allowed the kids to watch one movie on the big screen of the boat computer.

In the quieter times or during rough conditions, we took turns sleeping, reading or telling the kids stories.  The kids played games or watched movies on their iPads.  When things were stable, we would do an art project together, stretch, play music or have a dance party.  Then there was the regular business of cooking, cleaning, drying out the boat, and maintaining everyone’s hygiene.  Running the heat with little ventilation meant constant condensation, so it was an ongoing task to keep things dry inside.  There was a constant rotation of squabs and sleeping bags hung up by the heater to get dried out.

For this passage with a crew of five and the kids eating more than ever, we provisioned partially with freeze-dried meals.  When we were tired, it was a quick way of getting a balanced shot of nutrition inside of us.  Though we had four cups and four spoons aboard, we often just split and shared meals into two cups, which made for less spills and less clean-up.  No shower aboard, but hair was brushed, and teeth, ears, and bottoms were kept clean with fresh water.












On day 17 of our passage, James overlaid a weather file on the chart that made us both stop and stare. We were about 1300 nm from Cape Horn.  The forecast showed a monster low pressure system was approaching us, very fast and very powerful.  The diameter of the system was so wide that we had no way escaping it.  Wind forecasts were no greater than what we had already experienced in the Southern Ocean.  Our hope was to stay ahead of it, but we were sure to get some very strong winds and big seas.  We prepared for the big blow, taking extra care to make sure that everything on board was strapped down and put away carefully.


As seas grew bigger and winds increased over the next three days, we spent most of that time hunkered down in our berths, with little activity aside from necessary sail changes and charging batteries.  The boat speed combined with sea state created so much air in the water that it was difficult to use the water maker.

Outside were the largest seas I have seen since I started sailing.  They were magnificent dark blue walls that rose up behind us like mountains.  As they peaked and the sun shone through them, they turned crystalline blue, then broke, leaving the dark deep awash in sea of white foam.  Nature had never appeared more beautiful, dangerous and powerful to me.





With four reefs in the main and a fully battened storm jib, we were in the system and had big mile-maker days, covering just over 1000 nautical miles over the course of three days.  Wind speeds were between 40-50 knots, gusting 60-70.   Over the course of the depression, there were 3 times when a wave caught us just right, nearly knocking us on our side before James could correct the boat.

By first light on day 21, the wind at last abated, and we felt our muscles relax for the first time in days.  We were steadily moving East toward the Horn.  Winds had decreased from 60-70’s back to mid 30’s and we were feeling the pressure of the last few days slowly starting to dissolve.

We were approximately 300 nm west of the Diego Ramirez Islands and excited to know that we would be around the Horn within the next day and a half.  We were pointed on a course to go directly through the middle of the Drake, as far from the land as possible.  It felt a little strange to be so close to Chile and Argentina, places so familiar to us, and not stop, but I knew it could not be part of the plan.

The wind had laid down, but the sea state was still large, periodically bringing a big wave that slammed hard and loud into the side of the boat.  After days of being crammed together in one berth, Tormentina was stretching out, sleeping alone in the port side quarter berth.  James was lying on the nav station seat, boots and bibs still on, which he hadn’t taken off in 72 hours.  He had his eyes closed and was fighting a headache that was threatening to turn into a migraine, all from the intense pressure of maintaining everything during the big blow.  I was in the starboard berth, watching the instruments, while Raivo and Pearl both slept.

Out of nowhere, a huge wave hit the boat, just at the right angle, pushing us on our side.  “James!” I yelled, feeling the boat start to heel over dramatically as my body shifted in the berth.  I was hoping he could correct the boat before we got knocked on our side.

At the sound of my voice, James reached his hand for the pilot remote.  But before he could do anything, we accelerated fast to port, heeling over beyond the point of correction, approaching 90 degrees.

In slow motion, I saw James’ body lift into the air toward the port side of the boat.  I felt myself getting slammed inboard and quickly braced my body to make sure I would not crush the kids.  Raivo must have nudged his way to the opening of the berth in his sleep because as the boat continued heeling to port, one moment I felt his body next to mine, then immediately felt him slide out of the berth and his voice as he let out a long “Ahhhhh!”

I reached out and just missed grabbing his ankle, watching in horror as his body flew out of my reach, along the floor and past the center-line of the boat.

In the next instant, Raivo slid along the floor all the way to port , making contact with the ballast tank while James was simultaneously airbourne. Water rushed along the port-light window.  As the boat continued to roll past 100 degrees, both Raivo and James both hit the cabin top.  Next I saw the ocean churning on the other side of the Lexan windows at the top of the boat.  I heard Tormentina yell, “Mom!” from her berth.

After that a deafening silence filled my ears.  Time seemed to freeze and I felt this warm tingling feeling inside of me, expecting water to burst next into the boat or for us to fully roll 360.  I thought to myself that I was so glad we had really lived it to the fullest with our kids.  The last five years with them had been incredibly magical, so full of love and joy, and I felt we had experienced more with them in those few short years was more than what most people did with their children over a lifetime. I didn’t feel any regret and my last thought was that I if I could go backwards, I wouldn’t have changed a single thing.

Filled with this warm calm, everything stopped.

Water did not come rushing in, we did not roll upside down.  Like magic, the boat came back up the same way she had come. James and Raivo both dropped down to the floor.  My sense of hearing returned to me and I heard clanging in the galley as our cookpots rattled back into place and a few loose items dropped to the floor.

Raivo cried out, “Dad!” and James helped him up, asking him if he was okay.  He angrily replied, “Yes, but I bumped my head and my back!”

“Is everyone else okay?” James asked as he looked in Raivo’s eyes and gave him a thorough head-to-toe inspection.

I looked at Pearl, who was awake now.  “You alright?” I asked her. She couldn’t talk yet, but she gave me a nod.

Tormentina and I both replied, “Yes.”

James brought Raivo to me and he crawled back in the berth.  I held him tightly.  Then I tried to look him over myself, but he shrugged me off, and crawled down low in the berth, under the sleeping bag by my feet.

We asked Tormentina if she was sure she was okay, and she said, “Yes, but I got wet.  There’s water on this side and my head got squeezed between the gray spares boxes.”

James checked on her and tucked her back into her sleeping bag.

He then stood up and held onto the grab rails, looking up through the windows of the cockpit bubble.
 “Oh no,” he said.  “We lost the rig, Somira.”

Everything was quiet.  All we heard outside was the swirl of the ocean moving around us as we bobbed around, no longer under sail power.

“No,” I replied, in disbelief.

“Yes,” he repeated, his face awash with disappointment.

Tormentina said, “The mast is broken!  What are we going to do?  How are we going to sail the boat?”

James reassured her, “It’s okay, we’ll be fine.  We’re going to figure out a way to get into port.  Don’t worry, sweetheart.”

He was calm. Incredibly calm.  Too calm.

I felt strangely calm too.  It seemed like a situation like this should have put all of us in big panic.  If we were in a Hollywood movie, there would be some dramatic music playing in the background or someone would be screaming or running around.  But there we all were, all okay, no blood, no screaming, just present with the reality.  We were on our boat, like we had been so many countless days before, and as unreal as it seemed, the mast was broken.

We knew before we set off that losing the rig was a possibility, but we had hoped that this worst-case-scenario would never happen.  The kids had heard many epic stories from James’ sailing adventures before, had seen YouTube videos of boats losing their masts, and had been around enough sailors, especially in Auckland, to hear countless tales of boats getting dismasted, rolled and knocked down.

James put on his action suit quietly, meticulously checking his safety gear like normal, as if he was going out for any regular sail change.

“I need to go out and assess the situation,” he said.

“Let me know what you want me to do or if you need me to come out.” I told James.

“Okay,” he said.  “I want everyone to stay put in the berths.”  With that he stepped outside.

I held onto Pearl and kissed her tiny hand, who was awake and breast-feeding.  I tried to talk to Raivo, but he said, “I just want to go back to sleep.”

Tormentina was the opposite, wide awake and wanted to talk, chatting away non-stop.  She kept asking, “What are we going to do?  I can’t believe we broke the mast.  This is bad, this is really bad, isn’t it?  How are we going to get to France?”

“Don’t worry,” I said.  “We’re going figure out a way to get into port.  Everything is going to be okay.”  I took a deep breath, hoping that my promises would be fulfilled.

Part 4 continued HERE.

August 11, 2015

dismasted - auckland to puerto williams: part two

Story/Photos by Somira Sao

Below is another excerpt from my story about Anasazi Girl getting dismasted in March 2014. A shorter version is featured in the September 2015 issue of Yachting World (UK).  Part One of the original story can be read HERE.

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Amazingly, we were in motion again.

I got up slowly, stabilizing my body against the starboard ballast tank and the navigation seat.  Before I did anything – walk through the cabin, use the toilet, or put a pitcher on the stove to heat water – I sat down next to James to see where we were and what kind of conditions we were sailing. Sea state determines what we can and can’t do underway. In this case, we had stable NW breeze, were making good Easting, and seas were moderate. We were just over a thousand miles out of New Zealand.  The forecast showed that we would get a SW wind shift in 4-6 hours. Right now, it was safe to be active and get some things done inside the cabin.  

We commented on the temperature drop and discussed turning on the Eberspächer heater for the first time.  It would instantly take off the edge until the sun warmed the boat, but we decided to wait. The kids were asleep, warm inside the cocoon of a giant down sleeping bag.  In the meantime, hot drinks and staying layered in technical clothing would do the trick for the two of us.

We left port with 53 gallons of diesel and were guarding our fuel, which we needed to run the heater and the engine-driven alternator that charged our house batteries. Using minimal fuel was critical for keeping all our electronics running.  Careful conservation of all our resources on board while simultaneously not carrying too little or too much of anything was a key factor for successfully making all our long distance passages.

Sailing offshore often pulls forgotten memories to the surface for me.  Seeing our breaths as we spoke and our cups of tea steaming, I was brought far away from Anasazi Girl and back in time to our lives three years prior.

In March 2011, we were living in South America in a Peugeot Boxer cargo van (fitted out with a living interior) with our two oldest kids Tormentina and Raivo (ages 2 ½ and 6 months at the time).

Van Life / River Rats / Land Yacht
Puenta Bandera, Provincia de Santa Cruz - ARGENTINA (January 2011)

At that time, we had just fulfilled a dream project of making an unsupported descent of Argentina’s Rio Santa Cruz with the kids. The seeds for this dream were planted with a Google Earth map and a few trips over the river on the Charles Fuhr Bridge (Ruta 40) while were cycle touring this region.  

Seeds for dreams often begin here...
Google Earth view of the Rio Santa Cruz, Provincia de Santa Cruz - ARGENTINA

The river was an other-worldly blue, fed by the glacial melt of the Patagonian Ice cap and ran 400 kms from Lago Argentino to the Atlantic. The float was in a 15 foot hard shell canoe and lasted nine days. Alone in the wilderness, with very remote road access, we drank pure unfiltered water and passed landscapes of wind-blown pampas, abandoned estancias, basalt rock formations, saw guanaco & condor, and found Tehuelche artifacts.

Lago Argentino, a glacier-fed lake just outside of El Calafate - ARGENTINA
Tormentina (age 2) with the pampas, wind-blown sand dunes, and guanaco tracks.
Rio Santa Cruz, Provincia de Santa Cruz - ARGENTINA (January 2011)
Tormentina (2) and Raivo (3 months) and our simple living"scene" for 9 days on the river.
Rio Santa Cruz, Provincia de Santa Cruz - ARGENTINA (January 2011)
Our days of "basic" training for sailing long distance...
Everything we needed to survive unsupported for 400 kms are inside this 15' hard shell canoe.
Rio Santa Cruz, Provincia de Santa Cruz - ARGENTINA (January 2011)

After floating the Santa Cruz, we lived between southern Argentina and Chile so I could work shooting images. We spent time at the crag with an international tribe of climbers. That season, we met and re-connected with world-class athletes – like Rolando Garibotti, Sean Villanueva-O’Driscoll, Nico Favresse, Joel Kauffman, Daniel Jung, Sylvia Vidal, Tommy Caldwell, and the Huber Brothers.

Fidel Martinez Guirado highling above the Rio de Las Vueltas
El Chalten, Parque Nacional los Glaciares, Provincia de Santa Cruz - ARGENTINA (February 2011)
Sylvia Vidal  / sport climbing at La Platea
Parque Nacional los Glaciares, Provincia de Santa Cruz - ARGENTINA (February 2011)
L to R:  Daniel Jung, James & Raivo (age 4 months), Paulita Jones Volonte, & Nico Favresse
Parque Nacional los Glaciares, Provincia de Santa Cruz - ARGENITNA (February 2011)
Daniel Jung (on the wall) & Thomas Englbach / sport climbing at Commission
El Calafate, Provincia de Santa Cruz - ARGENTINA (February 2011)
We took road trips along desolate dirt roads, James always with one eye searching for undeveloped climbing areas and hidden crags of granite among thousands of sheep and the lone gauchos.

Joel Kauffman taking in the clean air on an idyllic run along the lake.
Lago San Martin, Provincia de Santa Cruz - ARGENTINA (February 2011)
Rocks, pampas and moody clouds.
Lago San Martin, Provincia de Santa Cruz - ARGENTINA (February 2011)
Jose in the kitchen of Senora Andretti.  Before leaving the "scene" in El Chalten for life on an estancia,
Jose carried loads for Kurt Albert on the first ascent of Royal Flush (44-pitch 5.12c, A2 Royal Flush, on the east pillar of FitzRoy).  We met him in celebration mode after he had fnished a project shearing 15,000 sheep.
Estancia Puesto Chacabucu, Lago San Martin - ARGENTINA (February 2011)
We eventually made our way south to the “end of the road” of Tierra de Fuego, to the port of Ushuaia, Argentina. The season was winding down and James found day work on foreign flagged expedition boats chartering Cape Horn & Antarctica.

We lived in the van at the yacht club, urban camping, paying for the use of the club’s facilities.

Then the first freezing cold nights arrived.

We slept layered in all our technical gear, surrounded in the morning by a cave of frost, breaths visible in the cold air. By the second morning like this, we knew it was time to head north.

This moment was a major turning point for us. As a family, life together was not about an existence of just living & working in a place. Neither was it just about being a tourist having a look around. What drove us to live was to go somewhere to DO something, to make friendships and deep human connections.

Always we strove to keep a healthy balance between working enough to live a simple life, while doing it in such a way that allowed us to be together as a family, to raise & teach our kids ourselves.

At this point, the river poject was over, our tribe had left Patagonia with the seasonal shift, and we were burned out on being on the road. It was hard for us to be around the expedition boats without the freedom to be on the water ourselves.

It was time to start a new life program.

We headed north & returned to El Chalten to store our canoe & river gear at Alejandro Capparo's house (the head park ranger at Parque Nacional Los Glaciares).

A couple weeks later we were in the big city of Santiago, camped out at the Herrara-Bravo house, trying to sell the van.  Once we found a buyer, we then moved into a small room at the Hotel Paris, located in the old cobble-stoned Iglesia San Francisco district of Santiago. We then sold everything else we owned (climbing & camping gear) to the young Chilean climbers.

We booked tickets to Panama and spent a week there looking for work.

Two weeks after that, we were in Maine, preparing to re-launch Anasazi Girl. By the middle of July 2011 we made our first offshore passage with the family, crossing the Atlantic in 21 days from Maine to France. Three years and three children later, we had made over 20,000 ocean miles together, crossed the North & South Atlantic, the equator, and made East-bound voyages through the Southern Ocean to the point where we were today.

Tormentina (2 1/2 years) and Raivo (9 months) on a Transatlantic voyage from Maine to France. (June 2011)
I felt a little choked up with the realization of how far we had come as a family since planning & provisioning for our small trip on the river. It had been a good exercise in risk management and expedition planning that helped shape the voyages we were to late rmake.

I thought about how those frosty mornings in the van had become such a pivotal moment in the course of our lives, and here we were again, about to cross that region where the idea to go sailing with the family had started.

We did turn the heat on that day, and the days that followed fell into a steady routine.  These were not the sunny, warm days of sitting in the cockpit with the kids, making sail changes together, and watching for dolphins, birds, and whales like in the Atlantic. The Southern Ocean was a completely different game altogether. This type of sailing was an intensive risk management program where being smart was vital for everyone’s safety and even the smallest actions of everyone aboard were carefully calculated.

(To be continued.)

June 29, 2015

mast plug / mast project part 3

by James Burwick / June 29, 2015

Preface:  This story dives into an area that people rarely visit. When sailors lose a rig, they go to a rig manufacturer and get a quote. What happens behind closed doors is the numbers come from the original players: naval architect, rig engineers and rigging suppliers. A replacement is calculated and priced.

In my case I was not after a replacement. I was after an economic and very safe solution to sail out of Puerto Williams, Chile (south shore of the Beagle Channel, 118km from Cape Horn) and finish what we started.  The plan: depart the Beagle Channel into the Southern Ocean to meet the SE trades, then rise up to the equator and circle the North Atlantic high to Lorient, France.  All this with “precious cargo” aboard – my family – my wife and 3 young sailors. Enough said about the obvious risk.

To make this happen we needed to search out used, donated or discounted parts.

The situation is complicated only by one thing: the lack of funding for a replacement carbon rig. My old carbon rig was super strong and withstood high compression loading in very demanding conditions. My boat is not a cruising boat, not even a cruiser racer, but instead a thoroughbred machine. She is 1 ton lighter than a Class 40 with more than 2 times the water ballast per side (750l vs. 1750l). She also sported a 92sqm mainsail on a boat that weighed 5.2T in Auckland (fully loaded for a 60 day non-stop passage between our “home ports” Auckland & Lorient).

Every one of my team knew the reality. I was uninsured, broke and injured both physically and mentally. We were going for it big time when we got caught by “the wave” with my name on it. 

Throughout this series I will take you along for this rebuild adventure, behind the scenes.  Remember I am a climber that went sailing. I have put in the miles but I am still learning. One day I hope to be able to call myself a real Sailor Man.


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The acceptance of not sailing out of here with the “voilure de fortune” was not easy. There was no way I was going to battle with the Armada de Chile after they saved my boat and my family. A classic keel stepped rig became the new focus. I started looking for a used mast to step on the keel beam. The issues became: acquiring mast foot and attaching it; fabricating partners and sealing the deck hole and making a custom gooseneck to hold the boom on; meanwhile finding the largest diameter to fit in the existing round hole.

I pushed aside the technical complications of doing all of this and searched for a column as I needed the dimensions of this to make the installation parts. As with every boat project you think it will take this amount of time and cost this much but the reality is always more than your estimate. Isn’t this why we love boats? I tried hard to be focused on the reality of the time/cost issue.

I first queried old friend Alex Simonis about the strength of the column I needed and sent him some numbers. He told me he was in the middle of a big project but could give me a ballpark figure. He requested that I send him the RM Max and he would get a closer figure when he had some time. Somehow I did not follow up on this. I continued to look for a rig, assuming a used mast from of a 50 ft cruising boat would do just fine. I dropped the ball. Big mistake.

“Is he dumber than a post?” I had heard that expression in rural Wyoming many times and here I was one of “thems”, uh-huh, acting dumber than a post. I proceeded down the wrong road of discovery. I dove in, wasting time – both mine and industry pros – looking for a used mast section in Chile, Argentina, USA, France, NZ, Australia, and Sweden. I wrote to everyone and his brother and their cousins. I really did not know what I needed and neither did they.

I even spent time calculating the possibility of constructing a wood-epoxy wing-mast with help from Gary Baigent and Eric Sponberg. The lack of tools, materials, and a workshop space on the island of 2900 inhabitants closed the door on this idea.  Gary Patten and Chris Bowman sent many drawings for alternative rigs. Joe Mckeown hooked me up with a friend of his in the Chilean lakes district with a woodworking shop capable of doing a wooden rig.

Countless people suggested using a power pole, lamp-post, tree-trunk, any old mast (“shove it in the hole and go, what are you waiting for?”) that it was over the top. It made me feel like I was really on an island of my own.

Spiderman on the boom, inspecting the mast stump - Club Naval de Yates Micalvi
Puerto Williams., Isla Navarino - CHILE / XII Región de Magallanes y de la Antártica Chilena

My goal was to find a solution that cost less than a deck cargo ride to a proper port where she could get fixed. Our remote location prohibited this action. At first it seemed logical to ship out of Ushuaia – the IMOCA 60s ship out of there – but this required the keel to come out of the boat, which was a major destructive process as the keel was permanently fixed. It got to the point where I was going to spend a huge amount of money and just have a broken boat in the next port. If I was going to go into debt again (which has happened), at least I could go sailing one more time. One more voyage. One more experience that had more value than money. Decisions, decisions, decisions…

Once again I was back to searching for rigs. I still did this without the most important number: The RM max. As it turned out this figure was so large we would have broken every potential column I found worldwide. Wrong, wrong, wrong, wrong.

I also did not consider carefully where I needed to start building. It was not at the keel like the former mast. Deck stepped was not an option either as I knew it would be complicated to fill the deck hole and build a compression post in winter in my location. I was just in denial about the reality of a keel stepped solution, concluding that I would just deal with it. Some pills I just swallow hard.

One close friend from NZ, Craig McDonald reminded me, “James you don’t do easy, that is not you.” These words helped me.



The turning point for this project came in one e-mail in the middle of the night (which is the only time the island’s satellite internet has enough speed to work relatively well, as the users are all asleep, except for me).

Uwe Jasperson at Jaz Marine (Cape Town) came up with an alternative suggestion. This man had previous history with me and my rig. I first met him in 2007 on arrival from Bermuda, then again in 2008 upon arrival from Auckland, then again in 2011 from Cape Verde (the third time with my family aboard). I departed South Africa in February 2007, trying to break the 38-day record (Derek Hatfield) to Tauranga. I was 5 days ahead of the record pace in the middle of nowhere when the base of this same mast exploded during a force 11 blow. Yes it was a gybe and I did a poor job of keeping my speed up. Lesson Learned.

I was 1200nm South of Cape Leeuwin, Australia. Uwe was one of the people I called to discuss ideas via sat phone. I worked with Uwe along with Pascal Conq to get my sorry ass into port unassisted. With the mast still in the boat wobbling around like a drunken sailor, I used all my mountain climbing rigging trickery to keep the rig upright in the boat.  After 9 days, flying only a storm jib, I made it into Albany, WA. I got a mail from my weather forecaster Ken Campbell (Commander’s Weather) introducing me to Peter Gilmour. Peter recommended Brett Burville at Windrush Yachts, saying he was the guy for the rebuild job. Brett re-engineered and repaired the mast in Freo, and off I went back into the Southern Ocean, around the world to Freo once again and on to Cape Horn where I cut it free into the deep. This experience created my bond for a lifetime with all these men.

In this situation, Uwe realized the complications of stepping a new mast on the deck were a non-issue. He proposed a solution that should have been obvious to me.

“I would prefer to keep your existing gooseneck. I would step the mast on the cut-down stump just above the gooseneck. At the moment you have a perfectly sealed mast gate. With a keel stepped mast you will have all the waterproofing issues etc.” 

He wanted me to cut a 1 inch cross-section off my existing mast stump (above the gooseneck) and send it to Cape Town. He then would make a carbon composite mast plug to be glued in. The new column would mount on this.
Drawing by Uwe Jasperson / Jaz Marine
A few days later came a drawing from Brett Burville with a similar solution and offer.

 Drawing by Brett Burville / Windrush Yachts

All of a sudden I was having a party excited about my future. It took me back to my house construction days, to the moment when we finally were finished with the foundation and the plywood sub floor was on. We were out of the dirt. Now we could build the structure. We always had a party – music, dancing, and beers – to celebrate.

This was a big deal. The composite “plug” would solve all of the following: water integrity, mast step, goose neck and compression issues. Thank you, Uwe and Brett. I could safely use the stump as they both knew the history of the section.

This was the work of Brett Burville. This section was re-engineered then rebuilt at his shop (Windrush Yachts) in Fremantle. This repair job was super. I remember quite well Brett finished in May and I was itching to get going. The locals tried to keep me around as winter was here and they told me, “Just stay we can go racing here in the winter series.” They told me about “The Bight” – The Great Australian Bight. I had never even heard of this piece of water. I was just worried about Bass Straight and the Tasman. They said I would have some breeze in the Bight. Well I did. I had 65 knots over the deck 2 times and did a double back to back uncontrolled gybe in one of these. I remember I called the Windrush shop on the sat phone after these events and we had a good laugh. She passed the test.

How stupid and lucky did I feel? Feeling foolish among friends who have respect for what you can and cannot do creates teamwork. I threw both drawings into my circle of knowledge. Having a team means reaching out to them no matter how much you think you know. Check, check, double-check. Andy Kensington (Pure Design + Engineering), Bobby Kleinschmit (Morelli + Melvin), Kevin Dibley (Dibley Marine Yacht Design), & Vincent Marsaudon (Lorima). Everyone confirmed that this was a brilliant solution. I was relieved to be out of the dirt and standing solid.

Drawing by James Burwick
At this point Kevin Dibley kindly and sensitively suggested I might want to contact someone I never even heard of – Mike Elley at Nosaka Applied Technology. Soft spoken as Kevin is, I listen to every word he says. He explained to me the niche in the industry that I did not fully understand:  Rig Engineering. He said it again, with a little more force. “Talk to him.  I discussed your project with him and he offered to help.” 

What I eventually learned was akin to this “You do not go to a M.D. to have your teeth worked on.” I assumed that naval architects designed rigs. Wrong again. Who are these rig engineering guys?  I found out. The few that I now know hang out behind the scenes and are into heavy metal concerts and stock car racing. They are also responsible for rigs in the fastest boats in the world today. Mike is a well-respected “rig ninja” flown in around the world to sort out high stakes complications with not enough time. A “miracle worker.” The depth of New Zealand marine industry pros is staggering.

This is one of the many super clear mails from Mike Elley:

“Hi James

I have a better idea what you are looking at now I have seen some pictures. With the stump cut short, right above the gooseneck I am happy with the lateral stability. I gather that the whole stump rotates through the deck so I am less concerned with the rotation now so long as the section is adequate to be rigged spreader less as per the old rig. The critical panel will be panel 1 given the change to a pin joint at the bottom so this should be looked at for buckling stability.

Regards your question at the junction of stump and new section I will give all my thoughts as terminology is confusing things a bit.


Drawings by Mikey Elley / Nosaka Applied Technologies
From top to bottom:
What I would call the mast “shoe” normally (the alloy part at the bottom of the section which will mate with the “tongue” on the new “step” on top of the stump) is commonly made from a thick aluminium plate with a fore/aft slot in the middle for the tongue. Often fabricated to the alloy plate is an upstand of shaped plate that fits inside your section closely (often welded to the shoe internally). This only needs to extend as far into the section as required to get fasteners into it around the base of the section (I think this is what you are asking?). There is a lot of compression here and not much moment so the internal upstand does not require a lot of length, say 75mm would be plenty and more than typical. The bottom of the shoe is usually curved for/aft to allow the rig to deal with different bends in that plane but is flat sideways. For this reason the shoe is usually quite thick as the mast is mainly sitting on the middle of it. In your case you want the load to distribute around the wall of the stump as well as possible so you might have a flat shoe and a thick step plate.
Now the tongue in this case doesn’t need to insert all that far into the shoe to do its job but it would be common to insert about 100mm and to have a bit of a taper on the top of it to make it easier to engage when stepping. If, as I will suggest, it’s made of alloy then it will have a weld cove around the bottom of it. This weld needs a corresponding radius around the slot in the shoe so the shoe can sit down without fouling the weld. The tongue might typically be about 20mm thick in this scale and is usually keyed through the step plate and welded top and bottom. It has to deal with any torque applied. 

For the “step” you have the option of making a composite version like Uwe drew or an alloy one. Either way it is important to support the wall of the old stump so it is constrained and cannot act like a free edge. It may be quite a good idea to increase the wall thickness at the edge by wrapping externally carbon fibre around the stump in the 90deg direction (around the hoop of the stump).
If you make a composite version it is important that the step with the tongue spans out to the edges rather than sitting in the middle.

For simplicity I would fabricate the step all in alloy. Just have a thick plate with the tongue and have an internal shaped plate like the shoe that fits inside the stump and also one that fits down outside over your extra 90deg wrap. Have these extend about 100mm if possible so some fasteners can be incorporated like Uwe drew. Fill the gap between the plates with glue when you fit it to the stump so there is no void and that will support the walls of the stump and transmit the compression efficiently.
 I hope that covers your questions about the junction.  Am sure more questions will arise about the section and panel 1 as you go forward.

 Regards
Mike”

I had offers from Uwe in SA, Brett in WA and Ronald Klingenberg Frey at Alwoplast in Valdivia, Chile to make this plug. I let my rig engineer Mike Elley decide.

A mast step, tongue, and shoe has been fabricated by Buzz Ballenger in Watsonville, CA. The plug has both inner and outer contact. It was made out of alloy then anodized. The installation will provide isolation between the carbon and the alloy with Spa bond 345. One layer of blue tape will be applied on the carbon surfaces. The plug will be dry fit. I will drill and tap 5mm holes and place machine screws. The plug will come out. The tape will come off, Spa bond 345 applied, then the plug slipped on. I will located the screw holes and insert the fasteners. This procedure will isolate the two materials as well as bond them.

Rewind… This discussion started with the line I had forgotten from Alex Simonis. “Get me the RM Max.” When I did get this figure, for the first time I understood why Anasazi Girl is such a great boat and why my project was even more complicated to solve.

More to follow: The search for a column and the design of the rig is up next.

Read full mast project HERE.
To help us get up and sailing again, please SUPPORT US.

June 18, 2015

June 8, 2015

in-port jury rig / finot-conq voilure de fortune / mast project part 2

by James Burwick / June 8, 2015

The first day in port after losing the rig last March, I called Pascal Conq at Finot-Conq to explain to him what had happened and the problem I had to solve.  Once again he listened to me patiently when things were pretty edgy.  This office has always offered their support during both of my around-the-world voyages via the three Great Capes.  

Pascal is consistently so cool, calm and collected, such a pleasure to converse with.  In all of my voyages he has always been there for me.  When I asked him how he can always be so cool, he told me he works on it every day.  So now I try to do the same.  I must also mention David de Premorel who is mostly behind the scenes but is a brilliant designer with unparalleled communication skills.  He undoubtedly shared in the work that came my way.

The plans below were calculated and drawn by Finot-Conq to finish our voyage (Cape Horn to Lorient).  As you can see, it is a simple solution of lifting up the boom and cutting down the trinquet.  There is very little compression in this configuration.  

Voilure de Fortune / Jury Rig
Drawings by Finot-Conq
Anasazi Girl / Open 40 - Original Sail Plan
Drawings by Finot-Conq
Anasazi Girl, Club Naval de Yates Micalvi, Puerto Williams
Vincent Marsaudon, Sophie Livory Boillot, and the rig engineers at Lorima also took a look the plans and confirmed the solution would work. Lorima for me builds the best composite masts in the world. Their portfolio of clients is a tour of the greatest ocean racers of the world.  My relationship with them goes beyond carbon & epoxy.  These people know the reality of deep ocean sailing.  What a gift to get the approval nod from them.

I knew it was possible to raise the boom but was relieved of the responsibility by confirmation from the pros. I am still just a sailor-man and need a team.  I am not yet the real deal Vendee Globe sailing machine.  We were instantly relieved.  Due to the remote location this made sense to us as a feasible solution to keep on sailing. 

However, Jorge Montenegro, the Maritime Governor of the region at the time of our rescue was not thrilled with this plan.  It was winter and I was in denial of my injuries.  He saw clearly with his experience gained from four prior deep ocean rescues under his command in the Armada de Chile.

Leaving from this location with me still injured and running on adrenaline with three young children aboard was wrong. As my close friend (world-renowned alpinist) Jack Tackle would say, "Which part of this did you miss?  The whole F@#*ing thing?"

Fortunately it was not our place to argue.  With time, I realized I was driven by what we call the "Human Factor". This can cause disaster in the wilderness.  I know better. This great man Montenegro saw this clearly.

Commandante Jorge Montenegro / Maritime Governor of Puerto Williams
As the adrenaline wore off after losing the rig, my physical body revealed the reality of where I was at.  While cutting the rig free after we were dismasted, another wave boarded the vessel.  I was pushed by the moving mast into the life lines.  The result was blood in my urine and one rib fractured in two places.  The months following I was invaded by a virus attacking my already weakened intestinal system by a life of adventure.  Eight months after dismasting, my health finally returned.

James at the Puerto Williams Naval Hospital several months after losing the rig.
This was not the first boat to break a mast and build an in-port jury rig.  It's been going on for centuries. A jury rig at sea is different than a jury rig in port. While I waited for Groupe Finot's drawings to arrive, Chris Bowman, Gary Patten, Joe Mckeown, Uwe Jaspersen, Brett Burville, Gary Baigent and Jon Patrick also sent drawings.

Yann Rochas our doctor in Lorient was the first one to try to contact us to make sure we were okay. The second email came from Peter Johnstone from Gunboats, who straight-away offered a job at his factory and a place to live for my family.  What a nice welcome back to port this was.

In the following days, emails came from the following industry players, all brain-storming for us. Without saying, they all realized that we had very little time to leave port or we would absolutely spend a winter season there, which would financially devastate us.  We received a huge boost of energy from "our tribe."

Simultaneously in this phase of planning arrived offers of assistance & ideas from:
Australia - Chris Bowman, Brett Burville (Windrush Yachts), Josh Fugill, Stu Bloomfield (Bloomfield Innovations)
New Zealand - Kevin Dibley (Dibley Marine Yacht Design), Richard Bearda (NZ Rigging), Andy Kensington (Pure Design & Engineering), Josh Tucker (North Sails New Zealand), Chris Mitchell (Applied Engineering Services), Gary Baigent, Garry Patten (Leading Edge Boatbuilders), Richard Thorpe (GAC Pindar), Nick Crabtree (GAC Pindar), Alex Vallings (C-Tech), Lynn Holland (C-Tech), Andy Ball, Jon Patrick, Mike Elley (Nosaka Applied Technology)
France - Pascal Conq (Finot-Conq), Vincent Marsaudon (Lorima), Sophie Livory Boillet (Lorima), Yann Rochas, Paul Fraisse (NKE), Dominique Yon (Facnor), Benoit Coville (Navtec France), Stephane Fauve (Incidences Sails France), Denis Glehen (GSEA Design)
Sweden - Torbjörn Linderson
Great Britain - Allen Clark (Owen & Clark Design), Merf Owen (Owen & Clark Design), and Andrew Pindar (GAC Pindar), Will Munroe (Sea-Me), Tom Reed (Scan-Strut)
South Africa - Uwe Jasperson (Jaz Marine), Alex Simonis (Simonis-Voogd)
USA - Bobby Kleinschmit (Morelli & Melvin), Buzz Ballenger (Ballenger Spars), Joe McKeowan, Pete Melvin (Morelli & Melvin), Bill Goggins (Harken), Skip Mattos (Harken), Scot Tempesta (Sailing Anarchy), Michael Hennessey (Dragon Ocean Racing), Rob Windsor, Mark Washeim (Doyle Sails Long Island), Jim Antrim (Antrim & Associates), Michael Reppy (Dolphin Spirit Racing), Peter Johnstone (Gunboat), Kame Richards (Pineapple Sails), Chuck Finch (Si-Tex Koden)
Denmark - Jan Møller (Lopolight)
Italy - Roberto Carraro (Antal), Enrico Tettamanti (Kamana Expeditions)
Argentina - Juan Pablo Calabrese, Guillermo Mariani, Diego Pasquariello
Chile - Ronald Klingenberg Frey (Alwoplast), Augustin Herrera-Bravo

The next step was to find a column and stick it in the boat classic style.  The search began. More to follow.

More about the mast project here: MAST PROJECT
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