Windwalker Projects Repower - 2008	Repower - 2008 Overview Step by Step Photos Project Costs Resources
Repower Project - 2008 Starting in June 2008, we upgraded Windwalker with a new engine. After a lot of dockside work, 37 days on the hard, and another several months of finish-up work at the dock, we declared victory just prior to New Year's of 2009. An extensive sea trial to the Florida Keys in the spring of 2009 completed the project. The new engine is a Westerbeke 44B, replacing a Volvo 2003T. Because the new engine is longer (4 cylinders versus 3), lower, and with a V-drive down-angle of 15 degrees instead of 20, the old beds had to be significantly modified. Other incompatibilities included a smaller exhaust size (2" vs 2-1/4"), electrical connections and control cables on the opposite side, and interference with the bilge pump and fresh water systems components, to name a few. As you may expect - there was a bit of engineering involved. The space was modeled using Drafix CAD, and drawings were made for the beds and engine setup, and a template was constructed from plywood to insure engine alignment before committing to glass. Cabinets and bulkhead components were removed, and work got started, but we didn't haulout until everything was ready so as to minimize the yard time which was going to cost $80/day after the first month. All in all, the haulout and engine swap went fairly smoothly and took only a week longer than planned. With temporary plumbing, electrical hookups and instrument panel, we splashed in October and made our way back to the dock (5 miles) under our own power. At the dock, we completed final plumbing and electrical, mounted the panel in the cockpit (which required the casting of a new fiberglass insert), mounted the refrigeration compressor and new hoses, hooking up the hot water heater, relocated the bilge pump, fresh water system, and oil change pump, and put all the woodwork back together. It was an extensive and complex project as you might expect, but by doing all the work ourselves, it was not as expensive as it could have been. The engine was purchased from Valiant in Texas at a good discount, and drop shipped to us in Florida from the Westerbeke plant in Massachusets. Setups and measurements, as well as custom fabrication of the compressor bracket and other parts was done in our garage, while much tear-down was done at our dock prior to entering the yard. For a step-by-step description, photographs, and an accounting of the costs involved, please see our project page.

Windwalker Projects

Repower - 2008

Repower - 2008

Repower Project - 2008

Starting in June 2008, we upgraded Windwalker with a new engine. After a lot of dockside work, 37 days on the hard, and another several months of finish-up work at the dock, we declared victory just prior to New Year's of 2009. An extensive sea trial to the Florida Keys in the spring of 2009 completed the project.

The new engine is a Westerbeke 44B, replacing a Volvo 2003T. Because the new engine is longer (4 cylinders versus 3), lower, and with a V-drive down-angle of 15 degrees instead of 20, the old beds had to be significantly modified. Other incompatibilities included a smaller exhaust size (2" vs 2-1/4"), electrical connections and control cables on the opposite side, and interference with the bilge pump and fresh water systems components, to name a few. As you may expect - there was a bit of engineering involved. The space was modeled using Drafix CAD, and drawings were made for the beds and engine setup, and a template was constructed from plywood to insure engine alignment before committing to glass.

Cabinets and bulkhead components were removed, and work got started, but we didn't haulout until everything was ready so as to minimize the yard time which was going to cost $80/day after the first month. All in all, the haulout and engine swap went fairly smoothly and took only a week longer than planned. With temporary plumbing, electrical hookups and instrument panel, we splashed in October and made our way back to the dock (5 miles) under our own power. At the dock, we completed final plumbing and electrical, mounted the panel in the cockpit (which required the casting of a new fiberglass insert), mounted the refrigeration compressor and new hoses, hooking up the hot water heater, relocated the bilge pump, fresh water system, and oil change pump, and put all the woodwork back together.

It was an extensive and complex project as you might expect, but by doing all the work ourselves, it was not as expensive as it could have been. The engine was purchased from Valiant in Texas at a good discount, and drop shipped to us in Florida from the Westerbeke plant in Massachusets. Setups and measurements, as well as custom fabrication of the compressor bracket and other parts was done in our garage, while much tear-down was done at our dock prior to entering the yard.

For a step-by-step description, photographs, and an accounting of the costs involved, please see our project page.