Emergency rudder & emergency propulsion

[sailbleu]

A lot has been said about rudder failure and/or engine failure , non of both are recommendable , to say the least .
Now and then an article pops-up on the board of boaters having to deal with one of these ordeals. I read them too and hope like most of you it never happens us .
But why not be prepared , in the past I often played with the idea of adding an emergency propulsion of some sort in case of engine breakdown , clogged diesel filter , you name it . I'm aware of the use of the dinghy and outboard for that purpose , even experimented with it just in case , but what if it's deflated for whatever reason ?
Our scheduled Trans-Atlantic crossing ( no dinghy on deck or davits) next year made me reflect and re-think on what's possible . I came up with a concept where my setup would allow a back up propulsion as well as an emergency rudder.
On the internet , youtube , we can find some devices to tow behind the boat , permitting a rudimentary steering , some diy's constructed their own redundancy systems , most of them have a not so interesting aesthetic outcome , but they do work .
My intention was to design a configuration which is not dominantly present ( keep the swim platform clear) , can be assembled & disassembled in no time and stored when not in use , and of course is multi-functional.

The solution was a hook-up system in combo with an outboard mount that can be taken away and also can be used for multiple purposes .
1 : E-propulsion
2 : E-rudder
3 : step for easy dinghy access and vice versa
4 : cruising hydro generator
5 : who knows ?

Let me guide you through my approach , it might be a jump start for others or give you some ideas , at your discretion.
The first few pictures illustrate the tests of both systems , what follows is how I tackled it , how it came about ; and supplementary comments


www.23hq.com/sailbleu/photo/63236736/original

Not a very clear image , but the rudder test was done on the leg between the islands of El Hierro ( most south west canary island) and La Palma last summer. 2000 meters deep I took no chances of something breaking off and attached a safety line to the davits above . The sails were in and the engine speed was 5kts , the main rudder was in brake mode an neutral position , the E-rudder performed flawlessly and made 360 turns without hesitation .


www.23hq.com/sailbleu/photo/63231413/original

The E-propulsion test was done on the island La Gomera ( Canary islands). Safety line obligatory , and you will notice there was quite some cavitation going on due to the outboard not going deep enough . A formality as I have 3 height positions on the outboard mount , here the middle was used , obviously the lower level is required . The throttle was halfway and check the next photo for the speed result .


www.23hq.com/sailbleu/photo/63231714/original

Sailing from the quay to the anchorage in the bay on the west side of La Gomera , I made 2,6 kts , half throttle , and outboard not properly immersed , not bad for a 6 HP 4stroke outboard pushing an 8 ton boat don't you agree .


www.23hq.com/sailbleu/photo/63231959/original

This is where it all started , I call this the adapter plate ( right) and the back plate ( left) . The adapter plate will remain visible at all time , this will permanently stay on the transom and the required back plat will offer some strength as the transom fiberglass is fairly thin . I remember a youtube presentation of boaters that had to construct an E-rudder ( for real) as their main rudder was gone . Several times the captain had to re-fix , re-screw the supports of the E-rudder on the transom as the screws were pulled out by the forces on that E-rudder that in fact was a cupboard door. The back part of the boat is not very thick glassed so I figured some distribution of the forces was necessary .


www.23hq.com/sailbleu/photo/63232269/original

I welded some nuts on the back of the back plate to tighten the adapter plate . Then our puppet show started . Getting that back plate to inside of the post rudder area is/was a challenge .Bear in mind it had to be sicaflexed to prevent water ingress , so doing this correct was essential not to get the quadrant and surrounding area all covered with that nasty stuff . Like a puppeteer the admiral had to lower the back plate by the two top ropes into an inaccessible space and at the same time I pulled the two ropes on the middle holes to the inside of the transom so I could get the adapter plate screwed to it .


ww.23hq.com/sailbleu/photo/63232556/original

Mark the holes


www.23hq.com/sailbleu/photo/63232579/original

Holes drilled , ropes in and pushing them in further so the fishing could start .


www.23hq.com/sailbleu/photo/63232671/original

It's a bite


www.23hq.com/sailbleu/photo/63232717/original

To give an idea of that maze inside . Obviously the back plate was too big to pass the hole for the main rudder stock , it had to sicaflexed , tight up and hanging without making a mess. Then lowered up to point where it touched the bottom and then I had to pulled it towards the inside of the transom . So a delicate synchronization job. Once I got one blot in we were home free .


www.23hq.com/sailbleu/photo/63232891/original

That wont go anywhere .


www.23hq.com/sailbleu/photo/63232911/original

This is option number 3 , see above on list of multiple purpose . I'll call it the dinghy step made of SS 316L sheet so it can stay on without oxidizing , the rest is made out of SS 304 that - as you know - stains after awhile .
The admiral always had some difficulties getting in or out the dinghy to and from the swim platform , this little SS accessory makes life easy for her . The arrows show where in a later stage I glued some anti slip patches on . Works great and the wife is happy , and when the wife is happy .....


www.23hq.com/sailbleu/photo/63233033/original

This photo tells the story .


www.23hq.com/sailbleu/photo/63233069/original

Rewind ( end of previous year) , back home I improvised a setup to copy the transom's angle so both the step and the outboard mount adapter are leveled . Also and very important the height to the water surface from the adapter plate Not being on the boat when I started the project I had to rely on the measurements given ( emailed ) to me by some friendly board members with a similar boat as we have . Thank you again Erkan , Alex and Chuck . The given numbers were correct , very helpful and allowed me to finish the project.


www.23hq.com/sailbleu/photo/63233392/original

As mentioned , knowing the exact angle of the transom with regards to the water surface ( the sea) was extremely important so both adapter and dinghy step are perfectly leveled .
I made a carton template , tried it on the wooden setup and then took it apart as a model for the SS sheet .


www.23hq.com/sailbleu/photo/63233628/original

Crucial angle !


www.23hq.com/sailbleu/photo/63233656/original

Nice puzzle


www.23hq.com/sailbleu/photo/63233674/original

The outboard-mount-adapter gradually getting together, the four pieces of threaded rod you see are actually short bolts welded to the in side of the adapter, each side of the adapter has a set of 4 . They're there to hold the slats in place. These slats slide in the adapter plate holders like a cupboard drawer .


www.23hq.com/sailbleu/photo/63233924/original


www.23hq.com/sailbleu/photo/63233956/original



www.23hq.com/sailbleu/photo/63233984/original


I forgot to mention that on this side of the adapter , the visible side , I welded nuts on the inside to screw on the base of the engine mount itself .


www.23hq.com/sailbleu/photo/63234033/original

It falls in place , note the red arrow , this an on welded stop to prevent the adapter ( and dinghy step) to drop to the rub rail where it could cause damage after awhile .


www.23hq.com/sailbleu/photo/63234147/original

Time for the E-rudder itself, where to start ? A piece of marine plywood and a rudder stock , or is it a rudder trunk , not sure ?


www.23hq.com/sailbleu/photo/63234198/original

Some research have led me to believe this shape is the most efficient shape for a rudder. Other research pointed out that the surface of an E-rudder should be 2/3 of that of the main rudder. I can now say to disagree with the surface theory. After my tests I find 50% of the main rudder is more than enough to get the boat steered . My luck is that I can raise the E-rudder so less surface is exposed to the water pressure . I'm convinced the first (highest) position on the mount is adequate to keep the boat's manual heading .


www.23hq.com/sailbleu/photo/63237187/original

No harm no foul . If it doesn't help it doesn't harm . What I trying to say it that some fiber glassing can only add to the strength of the rudder .


www.23hq.com/sailbleu/photo/63235627/original

One side done , flip side to go .

www.23hq.com/sailbleu/photo/63235652/original


Time to address the stock and bearing . I've cut some segments out to fit over the E-rudder and drilled four holes .


www.23hq.com/sailbleu/photo/63235714/original


www.23hq.com/sailbleu/photo/63235754/original

Once the fiberglass had cured I gave the rudder four coats of black dyed epoxy resin , seal it .


www.23hq.com/sailbleu/photo/63235806/original

How to fix the rudder to the mount ? The smaller plate with the 3 holes on the right hand side of the picture will be bolted to the mount. Seen next pics.


www.23hq.com/sailbleu/photo/63235858/original


www.23hq.com/sailbleu/photo/63235901/original

Try getting a hole this size without a proper sized drill or plasma cutter , cutting and grinding is an alternative.


www.23hq.com/sailbleu/photo/63235958/original

The lock pin allows the stock to come apart from the rudder , easy for storage.


www.23hq.com/sailbleu/photo/63236041/original

Important photo , the stock guide bearing is there for some additional support and to keep everything together . Unfortunately, the test showed this support was not up to the task . Therefor I had to reconfigure this bearing .

Btw the nut above is for the suspension between stock and outside top of the E-rudder. See photo down


www.23hq.com/sailbleu/photo/63236177/original

Only this feeble black nut preventing the complete rudder to swing from left to right , that didn't work .


www.23hq.com/sailbleu/photo/63236222/original

I took the bearing off and welded it on an SS plate the shape of the mount . I yet have to drill the correct holes when we get back to the boat in May as most of the parts remained on board.


www.23hq.com/sailbleu/photo/63236287/original

To illustrate how the outboard mount ( with E-rudder ) is held in position . Cross SS wires with tensioners stop any movement .


www.23hq.com/sailbleu/photo/63236381/original

I managed to attach the wires on eye bolts on the davits base plates .


www.23hq.com/sailbleu/photo/63236418/original

A view on the E-rudder stock >> and E-rudder itself


www.23hq.com/sailbleu/photo/63236473/original


www.23hq.com/sailbleu/photo/63236503/original


www.23hq.com/sailbleu/photo/63236527/original

Hope you enjoy this contribution


Kind regards

[MalcolmP]

Yet another impressive project Sailbleu, well done indeed looks great and very versatile. You should act as a consultant to Jeanneau when they are developing their new models!  Will add to Hints and Tips when I can in case the forum and/or photos ever disappear into the ether. Thx Malcolm

[erkan]

Great project sailblue.
I hope you never face emergency situations and never use it ;-)

[jy51]

Sailbeu,

like the others posting here I am amazed at your ingenuity and handicraft, well above my own ability, however, I don’t wish to sound mocking or contemptuous but we do have sails!

The auxiliary engine is a recent addition and although I appreciate that it has added safety and predictability to what was a very precarious pastime it is still possible to sail out of most predicaments when an engine fails. In the case of failure during close quarter manoeuvring, dropping the anchor could possibly be quicker that setting up a secondary propulsion system.

Many years ago in a French marina I witnessed locals who, after a day on the water would practice sailing back onto their berths. This intrigued me so much that during clement conditions I would try the same thing, obviously with engine on tick over as a guarantee. Regularly I would sail my 37 foot boat through the marina and onto my berth, something I haven’t yet had the nerve to try with my new 51 footer.

The confidence gained by this experience came in handy on two occasions, once, some years later whilst motoring up the Goulet de Brest with the wind on the nose I run over a very large fishing net which become trapped around our rudder, skeg and propeller, a situation that could have been very dangerous considering the narrowness of the channel and the proximity to the rocks, I unfurled the jib, pushed the main across and bore away to sail back down wind back to Camaret-sur-mer where at anchor I remove the offending netting.

The second occasion was a sail-drive oil seal failure while passage making from mainland Spain out to the Balearic Islands. There was very little choice other than sail at 1 knot in the general direction whilst debating what to do. We decided, rather than spoil out summer cruise we would continue out to the Islands and spent two eventful weeks sailing and anchoring around the Islands without an engine before sailing back to our base in Spain and directly onto our berth. Instead of turning a key and firing up the engine at the first signs of problems or pilotage we had to “think sailing” taking into consideration our vulnerability to the wind, current and surrounding obstacles at all times, it could be very slow going and frustrating having to tack many times to enter an anchorage whilst others simply motored in, but the sense of achievement made it all worthwhile.

[sailbleu]

JY51 ,

I do understand what you mean , but the thought of getting in a marina without any engine scares the living daylights out of me. I guess most boaters confronted with a situation like this would ask for a tow , or at least rig their dinghy for assistance.I believe my outboard could pull that off . I even tried on the spot circles with , really amazing what it can do ,.........in a settled sea and light wind that is .
I have always been a diehard fan for redundancy . For everything that is weight-wise possible I have a spare on board .Be it drive belts , coolant , oil , filters , waterpumps , fans etc. , I even go as far as a spare propeller , in 2013 I replaced the rigging/stays and I keep a spare for each stay on board .
Far fetched ? I know , probably a fetish or compulsive behavior. My burden to carry .

En when it gets to using the engine it becomes even worse , from the start I have always focused on saving the engine as much as possible , I pimped up our boat with a truck load of solar panels , windgen , generator and I even heat up the boilerwater through diesel Ebenspacher so I don't need to start the engine in either case.
Every cold start equals 10 hours of warm running , every start cold or warm is a load for the starter motor . I'm sure we agree the engine is the heart of a boat , even a sail yacht . It can save your boat , your lives .
Probably I need a psychiatrist , but then on the other hand my proclivity or mania doesn't harm anyone else.

I read your story of engine failure and I was flabbergasted by the way you kept your calm in such a distress.
My mind would be racing and full of ' what ifs ' . What if during the night whilst on an ' immobilized ' anchorage a storm and shore wind would make your anchor drag and push the boat to the cliffs ?
I believe these are actually stories you read now and then .

Some years ago there was a story on a Dutch board I frequented a lot at the time , out of the blue a member raised the question , more asking for advise , how to deal with a sailtrip from the Canaries to the Netherlands WITHOUT ENGINE !! His engine was toast and they wanted to cut corners ( $$$ ) by sailing the boat home and do the repair himself .
He was burned to the ground by the community up to a point where coastguard officials stepped ( on the board) and warned him it was absolutely illegal to start the trip knowing of the engine breakdown , and the neglect to consider he was risking the lives of all on board not to speak of the violation of marine safety regulation . Not sure what they did afterwards , but it became very ugly on that forum topic .

Another last year's story not from hear say , from those involved . A UK sailyacht has sail drive failure , gets ( I thought with help of the dinghy or was it a tow) in a Greek marina ( little island) in the Cyclades , no lifting facilities present , word goes round an the port police intervened . All papers were confiscated and an official survey had to be done after the repair to prove seaworthiness . Without a dry dock present that was impossible , so they were give an expensive solution , have a professional towboat from another island ( 20 miles away ) and tow them to the local dry dock there . Price >>>>> 10.000 Euro !! . The boat papers were retained so no escape was possible . They eventually got the tow boat in , OUCH .

Please don't get me wrong JY51 I do appreciate your view on the matter , I'm always open to suggestions and different opinions


Kind regards

[jy51]

Sailbleu,

i agree with all your comments, and as I said before, I am not here to mock, only to praise you on you interesting article and engineering skills.  

My comment was a reminder, and to play devil’s advocate simply stressing that although auxiliary engines and other means of backup propulsion are a safety factor, just like the GPS and electronic navigation aids we all rely on, they are only that, and we must not forget and never stop practicing the skills of seamanship.

Nowadays with an auxiliary engine, navigation aids and weather forecasting many boaters are too relaxed and don’t think far enough ahead or plan for what Mother Nature can throw at them.  I am not complacent and never think I know it all, we never stop learning, that’s what I personally find so enjoyable about sailing, every outing can turn up new problems to solve.

Vasco in a recent article about diesel biocides said to me never say never, but answering your comments on dragging at anchor in a storm, I can honestly say that I have never dragged, or if I have it has never been sufficient to cause a problem, but that’s not just luck, that’s years of learning and thinking ahead.  Please don’t think I’m being cocky, I’m sure, like everyone else, one day I could be in a situation that I simple haven’t or can’t cope with, but I do see many boats dragging and in most cases it can be put down to lack of seamanship skills.  In the mean time I can only wish I had the skills to work on my boat like you do.

[Charlie-Bravo]

Hi Sailbleu, and congratulations on your efforts, I too have contemplated the outboard stowage on a lowerable bracket, partly for the emergency propulsion reason, and also because it lowers it for ease getting it onto the tender, and you do have to put the outboard somewhere, so a lowering bracket seems a great idea. the rudder arrangement whilst good, I might resist, I like one thing that does a multiple of tasks and I am attempting not to have 'extra' bits in the limited area called a boat. I figure that some steering via string to the outboard might work, not as elaborate as your rudder of course, but just might help.

I agree with many points made by jy51, and do try to remember that one should be able to sail everywhere without a motor, ( I do try) and predict weather by the flight patten of birds and the type of cloud patterns in the sky, (I seem to be as bad at it as all the proffesionals)  and for many years I am told, folk did just that, ..... mostly due to a lack of engines, and weather computers ..... I also note hundreds of wrecks charted on and around the coast, and tales of many folk lost at sea, so perhaps quite a few weren't quite as good at it as history might suggest. I did marvel at one chap last year, he entered our marina under sail, gaff rigged wooden cutter of about 38 foot plus bow sprit, gliding passed the array of bow thruster equipped modern yachts, and single handed berthed into a pontoon berth even though a hammer head berth was available, ....... he just knew what he was doing, nothing rushed, all well planned, and something I can only aspire to be able to do with out fear of crunching the gel coat!

As Spanish chap once said, " to be prepared is half the victory " 

You seem well prepared ! Have a great time out there, and thanks for posting your fine works.

Wishing you fair winds and calm seas.
CB

[rene460]

Hi Sailbleu, another great project, well carried out.  I particularly admire the design which looks like it was meant to be there rather than something stuck on.  You and your admiral did well to get that backing plate in place, quite a tricky job.  

I hope that you never need to use it in anger, but I am sure you will sleep better on long journeys, knowing that you have it ready if required.  There are just enough news items about lost rudders to make us all a bit uncomfortable.

Interesting to see so clearly the side forces on the rudder.  We all know about balancing rudders, but this really only means reducing the load on the tiller or wheel mechanism.  The forces are still there to be carried by the rudder bearings.

rene460

[sailbleu]

Thank you gentlemen for the support and words of comfort .
I agree with the remarks given that some practice with sailing in emergencies and distress situations are advisable , a blind trust in redundancy systems is just not enough .
Therefor I think that for a major part I subconsciously use this redundancy hardware as Rene pointed out ' to sleep better knowing they're there ', for sure a false feeling of safety / security , but I'll take what I can get

Regards

[Trevor]

Once again sailbleu, and amazing step by step journey from the original thoughts and then the practical implementation of a complex project. It seems you are a project driven individual (my wife says that about me), with an extraordinary capability to personally see your imagination brought to life.

You encourage us to extend and try new ideas.

Many thanks,

Trevor

[sailbleu]

Dec 17, 2019 21:18:20 GMT Trevor said:

Once again sailbleu, and amazing step by step journey from the original thoughts and then the practical implementation of a complex project. It seems you are a project driven individual (my wife says that about me), with an extraordinary capability to personally see your imagination brought to life.

You encourage us to extend and try new ideas.

Many thanks,

Trevor

Thank you Trevor , please be assured I very much also love to read other boater's projects , it's fascinating to capture people's inventiveness on/for things . In this regard the internet has been a huge blessing from the sky .

Regards

[sailbleu]

For those interested in auxiliary/emergency equipment I just came across ( yesterday) this innovative idea.
Wish I would of seen it last year , it would most certainly effected my approach .
Not adequate as core/main equipment for bigger boats I guess , but in context of my personal E-rudder/drive project this is smack on .





Regards

[Trevor]

Sailbleu,

Thanks for sharing that video. That is outstanding. I’m not sure about super long distance range but the concept is fantastic.

Trevor

[MalcolmP]

Dec 4, 2019 18:27:43 GMT MalcolmP said:

Yet another impressive project Sailbleu, well done indeed looks great and very versatile. You should act as a consultant to Jeanneau when they are developing their new models!  Will add to Hints and Tips when I can in case the forum and/or photos ever disappear into the ether. Thx Malcolm

I added it to Hints and Tips awhile ago, but missed it off the index...

www.jeanneau-owners.com/hintsandtips/emergencyrudder.html

[ihsan]

Dec 17, 2019 9:56:54 GMT sailbleu said:

Thank you gentlemen for the support and words of comfort .
I agree with the remarks given that some practice with sailing in emergencies and distress situations are advisable , a blind trust in redundancy systems is just not enough .
Therefor I think that for a major part I subconsciously use this redundancy hardware as Rene pointed out ' to sleep better knowing they're there ', for sure a false feeling of safety / security , but I'll take what I can get

Regards

I went through your engineering steps, almost holding my breath. Congragulations. Safety always pays. As for the 6 hp, you can gain more thrust by altering the propeller size. Some manufacturers advise 5 pitch and 4 blades for heavy load.