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Zapdos
About
I bought Zapdos in May 2023 near Vancouver Island, British Columbia (BC), Canada and started refitting Zapdos in July 2023. Zapdos is a 1985(?) Bruce Robert’s design steel-hull sailboat. Zapdos might be a "Roberts 34" but we don't know when or where it was made or what model it is. Zapdos didn’t even have an HIN; at least, not one that we could find since the inside has a permanent layer of thick insullation installed. I named it Zapdos because I am converting it from diesel to electric; since its primary propulsion is wind and its secondary propulsion is electricity, I felt I must use a childhood icon to name it.
Project Goals
Overall, I wish for Zapdos to be an ethical ocean cruiser that easily supports liveaboard for 2 or 3 cozy people. I want Zapdos to be completely free of fossil fuels. With a primary 20kW electrical engine, powered by a 48V DC 30.72kWh battery array and 940W of solar panels, I will need to have backup propulsion at some point before crossing the Atlantic, like one or two outboard engines. Solar engergy will be the primary electrical input, but I plan on buying one or two 48V wind generators. The electric engine can also regen when cruising.
Since I now live in the Netherlands, I have a mid-term goal of sailing Zapdos down the west coast of the USA and Central America through the Panama Canal. I'll spend some time in the Caribean before heading north up east coast USA. Finally I'll travel accross the north Atlantic to western Europe. I purchased a steel hull sailboat, and I'm designing Zapdos with global freedom in mind. With a Starlink Performance kit, I can work remotely from nearly anywhere.
I'm extremely passionate about Zapdos. I aim to teach people about electrifying sailboats and living ethical, sustainable lifestyles.
Do you want to donate to Zapdos to help turn this into a reality? IBAN/Swift/Paypal options available. Also, do you have any feedback for me? Signal: yawnbox.01
Work Complete
| Status | Activity | Dollar Cost | Time Cost |
|---|---|---|---|
| In Progress | Learn to sail | — | Forever |
| Done | Purchase a steel hull sailboat with no engine | 7,000 CAD | 3 months |
| Done | Convert former 40HP diesel engine space to 20kW electric engine | 10,000 USD | 3 months |
| Done | Replace diesel tank with 48V DC battery array (30 kWh total) | 10,000 USD | 1 month |
| Done | Replace copper antifouling with silane–siloxane coating | 1,600 USD | 2 months |
Work In Progress
| Status | Activity | Dollar Cost | Time Cost |
|---|---|---|---|
| In Progress | Learn and design the electrical system (pdf) | - | months |
| In Progress | Install complete Victron 48V DC + 120V/240V AC system | 6,000 USD (so far) | months |
Not Started
| Status | Activity | Dollar Cost | Time Cost |
|---|---|---|---|
| Not Started | Purchase Victron gear for 24V and 12V systems | 750 USD (est.) | — |
| Not Started | Install solar arch and bimini for solar panels | 2,500 USD (so far) | — |
| Not Started | Build davit for dinghy on aft of bimini | 500 USD (est.) | — |
| Not Started | Build upgraded steering pedestal for electronics | 500 USD (est.) | — |
| Not Started | Purchase Raymarine autopilot, chartplotter, radar, GPS, VHF, transceiver | 15,000 USD (est.) | — |
| Not Started | Rebuild the head (compost toilet, water heater) | 1,000 USD (est.) | — |
| Not Started | Rebuild navigation station (not including electronics) | 250 USD (est.) | — |
| Not Started | Rebuild kitchen/galley (not including electronics) | 250 USD (est.) | — |
| Not Started | Install Raymarine mounts and systems | 500 USD (est.) | — |
| Not Started | Replace portlights with UV-treated acrylic or polycarbonate | 1,000 USD (est.) | — |
Current minimum estimated value: 37,100 USD
Current minimum estimated future value: 56,100 USD
Bottom Coating
After we pulled Zapdos out of the water, pressure washing it made paint chips fly off. Some chips to bare metal, but thankfully no leakage or rust. We had no choice but to refocus on scraping off the old bottom layers.
Thankfully, there was no rust anywhere on Zapdos. After over a month of manually gridning down to bare metal, we used two coats of black SeaCoat SeaPoxy 73, a two-part polyamide epoxy primer barrier coat. We then applied two coats of light gray SeaCoat SeaPoxy 73. Finally we applied two layers of SeaSpeed Ultra Clear, a hard-film silane–siloxane coating.
Port Side
Starboard Side
Bow, Stern and Keel
Dingy
Since we had leftover SeaCoat and SeaSpeed, I lightly sanded then coated the dingy with the same.
Top Deck
The top deck is still the original. I plan on sanding it down to a base layer without going to bare metal. I will give the top side fresh coats of electric yellow paint, and make any gray or black layers disappear.
Mast and Standing Riging
As far as I've been told and can tell, the mast and standing riging is in good shape. I'm sure some small improvements can be made, but I will hire someone to check on all of this for me before getting Zapdos back into the water.
I'm not sure where the Starlink Performance dish is going to get mounted.
I'm not sure where the future navigation gear will get mounted.
I'm not sure where the future 48V wind generators will get mounted.
Windlass and Anchor
The current 12V system is dead, and I'm not sure where the problem is. Fortunately I'm planning on removing and replacing most of it using Victron a 48-to-12 DC converter. I will replace the 12V battery that the windlass uses.
Long term I will replace the 12V windlass with a 48V windlass. I also plan on adding a second anchor.
The current anchor and chain lead are in good shape, but I need someone more experieinced than me to double check this.
Solar Arch
The most immediate next project is creating a strong solar arch and bimini so that the solar panels can finally be connected, and start charging up the battery array. In the above "top deck" photos, you can see some 316 stainless steel bars that will be used to create the arch and bimini. I have a large box of connector pieces for those pipes, but I still do not know how I'm going to mount all of that, especially strong enough to add a davit for the (heavy) dingy.
I chose two, high quality, large 470W panels that support high voltage output.
- Two Maxeon MAX3-470W-COM (pdf)
Cockpit
The current cockpit is fully exposed to sun, wind, rain, and waves. I plan on partially enclosing it over time, and once the solar arch and bimini is complete. Right now there are no electronics in the cockpit, which is one of the first things that needs to change.
Parts of the below-deck navigation station and cockpit will share various services and equipment. I'll document the necessary navigation equipment here. None of this has been purchased, it's simply my first attempt at pricing the gear I want to have. Keep in mind several important factors on these choices:
- I want Zapdos to not be limited in where it can go.
- When ocean cruising, autopilot needs to be solid.
- I want to maximize safety for myself, my crew, and everyone around me.
Raymarine Navigration and Communication
I need feedback here. Raymarine does not offer 48V DC gear. However they offer completely integrated systems. The cost is obscene. Is it worth it? Can I find deals on this gear? Please let me know.
Open Source Software Navigation
Since sharing this list, I've been informed about OpenPlotter. I will attempt to synthesize the open source options, but I still need help with finding compatible hardware. Currently reading the documetnation.
Indoor displays for RPI outputs
Zapdos' mechanical chain-and-sprocket steering element in the lazarette directly under the cockpit:
I want the autopilot to be as strong and reliable as possible. I want to go with a Type 2 - 24V autopilot since this is a steel sailboat and since there are no 48V autopilots on the market.
Lazarette
The lazarette has been compeltely redone and is still a work in progress. The diesel engine and deisel tank are obviously gone. The stench of diesel and oil is almost completely gone with the layer of paint put down on the insulation foam, and I sanded off a top layer of the marine plywood before painting it white too. Where the diesel tank was there is now a battery array. The starboard side will be made into a waterproof "jeffries tube" (think Star Trek) with most of the DC/AC electrical equipment. Sealing it from water will have the effect of minimizing any humming sounds from the Victron inverters. The custom mounting wall for the electronics was coated with anti-flame paint, hoping this is good enough to minimize electrical fires. The port side will be made into a comfortable natural latex foam bed and storage area. This bed and storage area will be left open The stern has an outside opening that I need to make into lockable storage.
Where we started from:
48V Batteries
- EG4-WP Waterproof Lithium Battery, 48V 100AH, Bluetooth, max 200A output
DC electric system
Companionway
The companionway has been completely rebuilt with marine grade plywood. However, it is not complete, as it needs siding and needs to be water proofed. Given the fragility of an electric engine directly under where waves will splash in, it's critical this be strongly considered. Completing this project is dependent on understanding how the navigation station and kitchen/galley will be integrated into the companionway.
The stair can be easily lifted up and placed in the aisle. It's like a cap on top of the very small electric engine. I do need to build in locking mechanisms so the stair does not rock, which is currently does in its incomplete state. It was built simply and strong, and has some weight to it. Protecting the engine is critical.
The companionway hatch needs to be compeltely redone. Because Zapdos is steel, I can make a custom door very strong. I'll aim to make it waterproof and air tight. In Canada it can get very cold, and one of the main areas where heat leaks is the current hatch. It also leaks rain water. I'll install a grade one bump-proof lock and deadbolt.
Navigation Station
Currently the 12V distribution panel and VHF is in the original navigation station area. however, the woodwork and drawers are very old and I do not like how the space is used. I'll modernize it and make better use of the space considering the starboard jeffreys tube and saloon.
Galley
The kitchen sink will be moved closer towards the bow and I've already purchased a larger, modern sink, and I'll use the same porthole for egress drainage. I want the location to move because I'm removing the head sink and the current location is awkward by the companionway. Two sinks on a sailboat this small is wasteful. The sink faucet will be upgraded to a modern, swining one. I'm a big (vegan) foodie and I want the galley size to accomodate the kitchen gear I want to have on board. Including:
- A Dometic CFX3 95DZ fridge/freezer
- A microwave
- A preasure cooker
- A high powered blender
- A coffee bean grinder
- A manual lever espresso machine
- A portable induction heat plate
Becuase of how I like to cook, there will be no gas and no oven.
Also in the galley will be the air conditioner and heater:
- EcoFlow Wave 2
I'll plan on buying a portable EcoFlow solar generator that will be independently solar-powered but still able to charge off the AC electrical system.
Head
The head will have its sink removed and that space will be where I install a water heater for hot showers. I'm planning on replacing the direct-discharge toilet into a composting toilet. Long-term I may install a holding tank.
Saloon
The main lounge will also be partially remade. All of the woodwork (bench and shelving) will stay and I will add custom made latex cusions with nylon ripstop. I do, however, want to find a creative way to have slide-out or pull-out tables. The center aisle is very narrow so there is not a lot of room, forcing creativity. I want the soloon to be as comfortable and useful as possible, and it needs to become a protected bed (anti-roll) for a large adult. Currently I am thinking about tables that pull up and be anti-roll siding when sleeping, and pulled up further to be used as laptop or eating tables.
Forward Cabin
The bow hatch is going to be remade into one that locks from both sides, and it will be an active, filtered air vent. I'm very conscious about CO2 buildup inside spaces, high air quality, and I've already purchased a low powered, high airflow electrical fan to accomplish this goal.
The forward cabin itself is already comfortable, but I will replcace the artificial foam with natural latex foam. It sleeps 2, so when all of this is complete, Zapdos will be able to sleep 4 to 5 people.
Thanks for reading!