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You can read Part One of this blog here

Part Two is here

Part Three is here

15 December, 2018-

Wow, time seems to fly these days.

Since my last update, I got the pair of gensets, removed them from their frames, and started figuring out how I was going to get them in below the decks.  There are several things that needed to be decided when I started.  Where do the exhausts go, how do they get fuel, where are the dedicated starter batteries attached to or if I am even going to use them,  how do I do the controls, (starters, chokes, etc, and in dual form…) 

Goliath by Dan Hennis
Tam says, “These darn gensets came and are further cluttering my parking spot!”
Goliath by Dan Hennis
Arrived well packed. But will they fit?
Goliath by Dan Hennis
Wahoooo! They’ll fit… once I strip off the framework.
Goliath choke linkage
Starboard choke linkage was a bit involved, but made adjustable.

The installations used the original isolation mounts and just sat them in 2 rails bolted to the frames and stringers of the hull.  The chokes required that I order the longest choke cable I could find, 120″, and then make linkages to make them couple up correctly. The controls required a bit of engineering scavenged from the RC world, but works great.  The linkages are different  from port to starboard, due to orientation placement.  I wanted both exhausts to exit via the pylon, so the gensets are placed accordingly. 

Goliath choke linkage
Starboard choke linkage was a bit involved, but made adjustable.
Goliath by Dan Hennis
Port choke linkage was simple.
Goliath port engine
Port engine almost ready to start. Firewalls in place.
Goliath choke cable ends
Had to make my own choke cable ends for the 10′ long cables.

I removed the mufflers from the gensets, and started making my own that would fit in the boat.  I might add, that with just the riser pipes with small expansion tanks in place, the generators are really loud… I am going to have to make sure the flex couplings and mufflers are really quiet when I finally get them fitted.  The exhaust plumbing is only roughed out at the moment.   

Goliath by Dan Hennis, Gensetts
Gensets in, now to redo the exhausts and local panels. But the decks look purty…
Goliath by Dan Hennis
That wasn’t too hard. Now to make the mountings.

The fuel tanks were discarded to the back of the shop until I needed to rob them for their usable parts. I opted for what I computed to be about 12 gallons I think, with a bottom contour to closely match the bottom of the hull. The top of the tank is slightly raised for a USCG requirement having to do with slosh and venting when in rough water.  I will know exactly what its quantity is when I fill it.  The first fuel pumping plan was to use a pair of engine-driven oscillation pumps that run off the crankcase venting.  I bought them, installed them, and primed the system up…  The port engine started and ran for about a minute and a half before starving and quit.  I never got the starboard engine to pop. Checked the system and found the pumps would not supply the needed fuel flow to the engines.  So I went to plan “B”.  That is to get a low pressure electric fuel pump and a controllable pressure regulator and re-plumb the system.  A month of waiting for parts and we are almost ready to try again.  (I’ll include pictures of the final plumbing in a future segment… Now on plan “C”.

Goliath fuel tank
1st gen. single center fuel tank after powder coating.
Goliath by Dan Hennis finished fuel tank
Finished 1st gen fuel tank. (later abandoned for a simpler dual system.)

Meanwhile, I assembled the upper pylon and yardarm onto the upper wheelhouse and painted it.  Wow, that Safety Yellow is bright.  All the passers-by can see this little girl for miles.  I guess that was the design.  I started installing some gear like antennas and navigation lights in it too.  I also started trying to figure out the interior.  Ordered and received the interior lighting.  I am planning on 12 volt LED components originally intended for a home, but I will not be using the included 120 VAC-12 VDC transformers.  I have been holding off installing windows till I absolutely had to.  It makes it easier to do the wiring and fitting of other pieces.  I cut and rough-fit the polished stainless steel hand rails that will be for accessing the fore deck from the aft.  (I’ll include pictures of them in a future segment.)

Goliath upper wheelhouse
Upper Wheelhouse painted and some parts installed. Wow it’s bright.
Goliath second position light
The second position light is for potential night tows.

I finished up more in the main deck plating, ordered venting grills, and tried to make contact with somebody, ANYBODY in authority to discuss things like USCG and ABYC requirements for venting, flotation, placarding, and a dozen other things that might be of concern to the prospective commercial buyer. 

(There is no publicly acceptable picture to convey my utter frustration…)

(Caution, rant approaching…)

I am here to tell you that the local Detachment of the USCG would not so much as even consider talking to me about it, much less come and see it.  They even REFUSED to come look at the build in my shop!  I never got a call back from the ABYC reps.  I contacted the Missouri Water patrol (an arm of the State Police), and they were aware of it, but had no interest in the requirements (or even leaving their offices), except to tell me that they would inspect it when it was done to see I had it secured well to the trailer,… that it had all the proper paperwork for registration,… and they might, … come inspect for the required HIN (Hull Identification Numbers) placements…  I later got a call back saying that no visit was planned.  I will have to trailer it to the office in the middle of Springfield, and park it in their tiny parking lot for the obligatory inspection.  I am seeing a real disconnect here in the area of requirements and application and conformity. 

This is all included here with this explanation.  Several months back during the Summer sometime, there was a commercial duck-boat accident in Branson, where it went out, loaded with Pax, in stormy conditions, poorly fitted for emergency gear, and a whole bunch of tourists lost their lives when it sank in the storm.  I do not want to have that kind of thing happen to any of my builds.  I can not control the usage, maintenance, etc.  But I can at least build it safe in the first place.  Then I can have a clear conscience when I hand the keys to the new owner.  So I am just a bit perplexed as to the “commercial requirements” that may apply.  This is of no interest to the builder that is going to use a boat for personal use, I.E. a “pleasure craft.”  Needless to say, I will be making sure I have some safety gear more than for a personal boat.

Now back to our
regularly scheduled boat building programming… 

I installed dual AC-to-DC battery chargers next to the gensets, and shortened the power cords to fit the application.

Goliath chargers
Mounting the twin 17 amp, 48 volt AC to DC Chargers. (port side choke linkage is simpler)

I got the aluminum duct castings (prop nozzles), from the foundry on the 29th of October while on my way to visit my son’s family in Idaho.  Started finishing them and blueprinting them to the drive assemblies on the 8th of November.  This operation is tedious work, and is quite time consuming.  There is about 1/8″ clearance around the props on these things, so they will create the desired thrust.  That requires the hand fitting to each lower anti-cavitation plate, and then added bracing to the skegs, etc.  When the drive castings for the outboards are made, they are not as precision as one might think.  For now, I’ll show a preliminary fitting of the duct, but when the installation is complete, I will revisit this element of the build.

Goliath ABS master pattern
The painted ABS master pattern is on the right. I ordered one extra while they were at it.
Goliath by Dan Hennis
Before starting the “blueprinting”, I made reference lines to measure by. Remember, only 1/8″ of tip clearance is allowed.
Goliath by Dan Hennis
“Blueprinting”, includes keeping them exactly true to the lines of thrust.
Goliath by Dan Hennis
Starboard nozzle about ready for drilling and mounting structure.

After building and installing it, I decided to remove and reshape the aft, center pedestal for the twin bollard, so the motor hatch would open a bit better.  I have an agreement with the shop where I have all my aluminum welding done.  I get a better price if when I bring in parts, that they are “fit-in” jobs, and no real rush.  Took about a week to get it re-welded.  I then re-sealed, and installed. Works like designed now.

Goliath modified aft
Modified aft, center twin-bitt bollard ped so the hatch will now function properly…

I got the first small bilge pump installed with the float switch and mounting bracket and all pre-wired out to the electrical raceway.

It seems like I do more removing of several parts, to install another part these days.  That was the case with the firewalls fore and aft of the gensets.  Installed aft firewalls for gensets.  For USCG regs, I found it would be better to wall them off, and provide separate ventilation for them, for both cooling and fume mitigation.  I got some 4′ x 10′ sheets of 18 Ga. (.040) aluminum sheet for this task.  I also cut and installed firewalls just ahead of the motorbay.

Goliath port motorbay firewall
Port Motorbay firewall. Motor bay will be completely walled off and vented.

Since the battery banks will be sealed AGM cells from NorthStar, I won’t have to provide fans and venting for them. However, I may put some in for cooling. That is it for now, Hope all have a very happy and peaceful Christmas and superb start to an exciting New Year.

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One Response to First attempt at making a steel boat, the Goliath-Pt 4

  1. Yacht man says:

    Interesting and good job, man. At what stage are you now?

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