Operation POOTANK (Part 2)

Plumbing in the holding tank was a pig of a job.  The theory is all very simple: run a few lengths of large diameter sanitary hose, screw on a couple of diverter valves and link everything up securely with jubilee clips.  In practice the sanitary hose seems to jam at every bend and we had to work it into position, sometimes centimetre by centimetre, with Nicky pulling at one end and me pushing at the other.  I am now covered in bruises and have discovered muscles I never knew I had from being scrunched up in awkward positions (normally head down in the bottom of a locker wishing I had double-jointed arms!).

There was one access cover to the area underneath the toilet that I could have removed to make things slightly easier but getting to it would have meant pulling apart a whole section of the heating pipework so I went for the 'bruises and expletives' option instead.

Rustler Yachts go to extreme lengths to ensure that all of the equipment and machinery on their yachts can be removed relatively easily, which is a really important factor as we are planning to be away for a long time and, no doubt, equipment will wear out and need to be replaced.  I sometimes have doubts about the 'fixability' of some other yachts when reading that they have been constructed as completed modules which are lowered into the hull and then the deck fitted on top afterwards.  Aside from the quality of woodwork by Rustlers, I was also really impressed with their attention to detail when I had to replace an exhaust silencer a couple of years ago; it initially looked as if major surgery would be required to gain access by pulling apart the companionway steps.  On closer inspection I discovered that the wooden frames and other potential obstructions to removing the silencer had all been carefully chamfered so that by turning the silencer several times as you removed it, it slid out beautifully through a space you just wouldn't think was large enough.

Half-way through
enlarging the hole

Rustler Yachts' attention to detail and build quality was again revealed this weekend when we came to run the pipework for the toilet.  The butyl rubber hosing we had chosen was a few millimetres larger in diameter than the previous sanitary hose.  'Not a problem' I thought, as enlarging the holes through any wooden bulkheads was pretty easy stuff.  The hole the pipe runs through to connect to the toilet was, however, a different matter.  I expected the platform the toilet sits on to be made of two layers of GRP with a layer of marine plywood sandwiched in between to provide rigidity; a fairly standard marine construction method.  Perhaps Rustler Yachts wanted to make absolutely sure no moisture would degrade the core, or perhaps they just wanted the strongest possible platform for the toilet, but either way I was impressed when I discovered that the platform was made from thick aluminium with veneers of GRP.
It did, however, make enlarging the hole for the pipe a slow and messy job with lots of aluminium dust getting everywhere in the process.  Just as well Nicky had suggested that we bring the vacuum cleaner from home with us.

So, after a day and a half of work cajoling the pipes into position, replacing all of the toilet seals plus cleaning everything in sight, we now have a fully refurbished aft heads with a brand new holding tank fitted.  There is one connection to the holding tank that I will change from a 90 degree bend to a straight connection to get a better pipe run but, apart from that simple job, the pipework is complete and the toilet is fully functional again.

Fitting the holding tank was always going to be a big task but it sets us up for cruising in the Mediterranean and other beautiful locations.  Having the extra 'black water' tank capacity means we will be able to enjoy idyllic anchorages for several days without spoiling the water quality even if we have guests onboard.

Around pulling pipes into position, Nicky also found time to replace the sealant around the galley sink area.  With far more patience than I have and a knack of working with silicon sealant that escapes me, the new bead of white sealant looks immaculate.

The only remaining task for the holding tank project is to connect up the contents gauge.  The electrical connections will be easy but running the cables from the wet-locker area to the chart table will, I am sure, provide some 'entertainment' for a few hours; it may even prove to be a big enough task for a Part 3 report on Operation POOTANK.