Lets Get It Fixed In New Zealand
Repairs, Maintenance and Upgrade Planning
Leaving the Caribbean and heading across the Pacific, we were looking forward to reaching the boat-friendly shores of New Zealand. We had planned a list of repairs, maintenance and boat-improvement projects, knowing that New Zealand had a knowledgeable marine industry. Most boat items we required were available off the shelf. This was a far cry from what we had been able to access. Additionally, we planned to temporarily import Eleuthera into New Zealand, meaning the boat repairs would be exempt from GST.
Boat maintenance occupies nearly 50% of normal cruising life, with both planned and mostly unplanned jobs. Every boat has a “To Do” list, and inevitably, many things never make it to the top of the list. The most satisfactory job is the unplanned task, which is completed easily. This is then added to the list and immediately crossed off – feels like progress. Boat improvement remains a low priority, with repairs taking precedence.
Also, cruising in relatively remote locations means both parts and expertise are generally expensive and difficult to come by. Visiting friends become couriers bringing an array of parts and spares with them. The DIY approach, aided by YouTube videos and Google searches, means most repairs can be sorted. Fellow cruisers are also a source of information and often specialist tools if required. There aren’t many problems which haven’t been solved before.
We arrived in New Zealand at the end of October 2024. We had been in contact with a number of suppliers about the big project to replace the refrigeration on the boat. Eleuthera was originally fitted with a large Fridge and Freezer powered by water cooled 240v compressors. These were now 20 years old, and while we had tried to upgrade them along the way, but they were passed their use-by date. On the trip down from Tonga we had had some electrical problems in the 240v switchboard, so that also made the upgrade list, along with a raft of other small projects.
Little did we realise that this would turn into nearly 6 months of continuous work. We were trying to get the boat ready to depart New Zealand for French Polynesia and were continuously delayed.
Switchboard Upgrade
On arrival at Marsden Cove https://marsdencovemarina.co.nz/, we engaged a local electrician to replace the entire 240V switchboard. The old one seemed to have some electrical damage, and also the enclosures were damaged.
Two new enclosures and 28 new circuit breakers later, we were able to get an NZ Electrical Warrant of Fitness. We could then plug into the shore power. In the process, we discovered another faulty contactor, which was also replaced.
Victron Inverter Chargers
Eleuthera has 2 Victron 5Kw Quattro inverter chargers and one of these had failed with suspected saltwater damage. Removing the offending unit it was sent off Lusty and Blundell for repair. Reports came back that a circuit board had failed and needed to be replaced. The good news was, they were in stock. As we had purchased them new in Malta in 2021 they should be under the 5 year warranty.
This relief was short-lived. We discovered that Victron offer a warranty from the date of manufacture, not the date of purchase. Apparently, these units were 5 years old when we purchased them. Makes you realise the benefits of NZ consumer laws, where warranties are from the date of purchase.
With the unit re-installed everything came back online. However, for no apparent reason the unit was to fail again twice more. Luckily these repairs were under warranty as it was the same circuit board failing each time. 3rd time lucky the system has come right and we can only assume a bad batch of circuit boards.
Anchor Winch
One of the fears when cruising is the anchor winch failing and having to hoist the anchor by hand. Eleuthera carries 140m of 12mm chain and a 50kg anchor which has a combined weight in excess of 500kg. Anchoring in 20-25m deep water meant we often had +100m of chain out so a reliable winch is important.
We had come across several boats whose winches had failed for various reasons which severely limited their cruising options. A full service of our winch was a priority before we had a problem. With new bearings, motor brushes, oil changed and serviced we should be good for the next few years. We also now carry a range of essential spares for the winch.
Hull Repairs
When we were in the Galapagos, one of the crew noticed some small hairline cracks in the starboard hull. These were above the water line in the area of the main beam. We did a major inspection of this area, both inside and out to check there was no structural damage. We then marked the ends of the cracks but found that no further movement occurred.
As a boatyard job this was also on the list when we hauled out in March 2025. After grinding the damaged area back it became apparent that the damage was largely cosmetic. The crack had occurred on a join in the original layup of the hull. The repair, now a couple of thousand miles old, has held with no other issues.
Rudder Bearings.
We had replaced the port lower rudder bearing housing in Trinidad a couple of years earlier. We were unable to get access to the starboard one, because the fridge compressors impeded access. With the fridge upgrade and removal of these compressors came the opportunity to replace the starboard one.
Once again a boatyard job with parts coming direct from France through International Boat Spares. After much dusty cutting and grinding, the old housing was removed from the hull. Following some repairs a new lower housing, the bearing was fitted. Luckily, we had the services of Prevek an excellent fibreglass guy to help.
Fridge Upgrade
All of the fridges were due for replacement when we were in the boatyard in Whangarei. The plan was to remove the old built-in units and replace them with off-the-shelf units. This initially seemed a straightforward job.
As with all boat jobs, reality was slightly different. The door on the galley fridge had fallen off during some bad weather in the Mediterranean. It had then been leaking for some time. Consequently, some of the cabinetry had gone rotten and would also need replacing before the new units could be installed.
The large fridge and freezer had been built into the boat. This construction required nearly a week to demolish the cabinets and remove the insulation. This was followed by the removal of the compressors and other plumbing and wiring. These had also been leaking water and the floor and surrounding wood work had also rotted away.
With big jobs like this nowhere on the yacht is tidy.
As part of the deal with the boatyard, we had advised them some months earlier that we would need a boatbuilder/cabinetmaker to help with this project. We followed up when we arrived in New Zealand and they looked surprised. They seemed to have no memory of previous conversations despite the emails. After a few days we were finally allocated a carpenter. He seemed to know what he was doing, although, the pace of activity caused us to name him “Lightning”.
As the new fridge units are smaller in volume than the old ones we have also installed a fridge/freezer unit under the seat at the dining table. This was a very tight fit and with few installation instructions it was trial and error. The first attempt at plywood lids was not successful so the second version has insulated fibreglass ones which seem more successful.
With close supervision, new cabinetry was constructed for the fridge unit. These are modular Isotherm units off the shelf. They only required electrical connections and ventilation as they are air-cooled. The old units were water-cooled, so we also took the opportunity to remove the through-hull water intakes for these. Eleuthera now has only 13 through-hull fittings below the waterline!
The new fridges draw in a total around 20A if they are all running at once. The old 240V system could draw in excess of 80A from the batteries. No longer having water cooled compressors, and the maintenance associated with this, and significantly lowered the energy consumption. The new refrigeration is a great success.
New Oven
An unexpected upgrade came about when Hew cleaned the existing oven. Proudly standing back from a sparkling clean appliance, he discovered it no longer worked. Given it was over 15 years old, a trip to Harvey Norman saw us return with a new oven. This was installed into the existing space with only minor modifications. We were beginning to wonder what else could go wrong.
Generator Upgrades and Maintenance
Our trusty Kohler generator has run over 10,000 hours and is an integral part of running the boat charging batteries, powering the watermaker, dive tank compressor and also the oven and washing machine. While it has been very reliable we thought it deserved a New Zealand birthday.
Subsequently, we have replaced the engine mounts, the starter motor, and some pipework. We have also serviced the injectors and installed an exhaust blower in the generator space to keep the whole system cooler.
Now we have expanded our solar array and changed to Lithium batteries we expect we will run the generator less for battery charging which should see the annual running time drop from around 8-900 to 4-500 hours.
Solar Panel Upgrades
We have had two Rutland wind generators on the stern doing their thing since we have owned Eleuthera . These both failed on our trip from Tonga to New Zealand and on inspection needed major repairs if we were to retain them. We decided instead to install additional solar panels using the wind generator poles to mount them on the stern. The excellent stainless framework was done by Terry at Alloy Stainless & Marine Ltd https://asmltd.co.nz/.
A new frame was fabricated in Whangarei and craned into place. Aesthetically an improvement over the wind generators as well as providing sun protection for the dinghy. 1000w of silent solar replaced 400w of sometimes noisy wind generator for about the same cost as repairing the wind generators.
Lithium Batteries
While installing the new solar panels and maintaining the generator we discovered that one of our two banks of batteries had failed and the other bank was failing. All of this about the time we were due to depart New Zealand meant we had to make some quick decisions. Since purchasing Eleuthera we have been upgrading the battery charging and control systems expecting that one day we would move to Lithium batteries.
To this end we had installed Victron Quattro inverter chargers, Victron MPPT solar controllers and a Cerbo to manage it all in Malta in 2021. The next step was an upgrade to the engine alternators when we installed Balmar 24V 160A alternators with Wakespeed regulators and DC to DC chargers in St Martin in 2023. These systems could charge Lithium batteries with relatively simple changes to the software setup.
The price of Lithium batteries has come down dramatically over the past few years and now they are similarly priced to equivalent capacity AGM batteries. On the basis of some discussions at the Auckland Boat Show earlier in the year we decided to install Juice batteries from Enertech in Auckland as they comply with the Australian and NZ standards and seemed to have a good reputation.
So, it was out with 8 x 65kg 12v AGM batteries and in with 3 x 35kg 24v Juice batteries from Enertec Marine https://enertecmarine.co.nz/, a weight reduction of 400kg. The new batteries fitted into the existing battery trays but required new cables and fuses to connect them all into the existing system. All of this took about a week and some back and forth with the suppliers to get it all to connect up to the Victron Cerbo. With some programming changes on the charging profiles, we were good to go. The electrical work was done by Paul Watson at Watto Electrical https://www.wattos.co.nz/
What a difference these batteries make. With the same installed capacity of 780Ah we can now use 80% of the capacity rather than 40% with the AGM’s. Charging rates are hugely faster with no tapering in charge rates that you get with AGM’s. Typically we use about 25% of our battery capacity overnight running refrigeration, lighting, internet and other things. With the old batteries we had to charge them fully at the end of each day to get through the night. Now we just check that they are at 70% or better and our increased solar array seems to easily charge everything unless it is raining and cloudy.
Watermaker
Our watermaker runs on 240v and makes around 160l per hour. It is a simple component system and has reliably produced water for over 1000 hours (160t of water!). To give it a birthday we have replaced all the high pressure lines and fittings with stainless steel ones and also installed a new membrane housing as the end caps were leaking. While we only needed new end caps we were fortunate to obtain a whole new housing very cheaply which we have fitted in its place. With the oil changed in the high pressure pump we should be good for another 1000 hours at least.
Staunchion Bases
Eleuthera was originally fitted with cast aluminium staunchion bases bolted to the deck with a stainless steel bolt and fitted with a stainless steel upright, an electrolysis nightmare. They were always a bit suspect and when we casually pulled one out of the deck with a spinnaker sheet it was obvious that corrosion was a real problem.
The solution was to fabricate stainless steel bases which would mount in the same holes and fit the same uprights. We had these made locally and, when in the boatyard, we changed them over. Detaching the old bases from the boat was an interesting investigation into some very tight spaces unseen since Eleuthera was new. With double jointed wrists and the usual bodily contortions we managed to remove the old bases. The adventure including dropping a spanner behind a wall which was only retrievable with a strong magnet.
The uprights were corroded into the bases so several hours were spent carefully cutting away the aluminium before they could be reused. The new bases were fitted after a few fibreglass repairs on some old damage and we feel a lot more confident in the whole system. The horizontal wires were also replaced at the same time as the old ones had some burrs and were showing signs of corrosion.
Main Engine Upgrades
Our main engines are Nanni diesels based on the Toyota 1KZT engine commonly used in Hilux and Landcruiser. They have run over 5000 hours each and well maintained they have a very long life and we expect they will run for many years yet.
We installed catch tanks on the rocker cover breathers to try and reduce any chance of excess oil fuelling the engines and causing them to run away uncontrollably. We also serviced the injectors and the engines now run much more smoothly with almost no visible exhaust smoke.
Through Hull Fittings and Other Openings
We had replaced all the underwater through hull fittings in Sicily with TruDesign composite ones. Unfortunately, the installation was not well done and at least one had developed a small leak in our travels and, while not serious, was irritating. Having bilge pump alarms going off daily is never a good thing.
‘While out of the water in the boatyard we took the opportunity to remove and reseal the main inlets in each hull which has solved the problem.
Also under the bridge deck were 2 scuppers one of which was the air intake into the aft locker where they main engines draw their air from. The other is the scupper drain immediately before the step down into the cabin. The problem with these is, in a following sea, water tended come up the scuppers with the result that the aft locker was damp and salty and unexpected spurts of water would come out of the cockpit drain.
The solution was to close off the underside vents into the aft locker and fit vents above deck from the cockpit instead. The locker and engines now get clean dry air rather than damp salty stuff.
The unexpected shower from the cockpit drain has been eliminated by fitting a baffle which allows free draining from above but prevents water coming up from underneath.
Safety Gear Upgrades
As part of gaining our Offshore Vessel Certificate we have had to update the safety equipment onboard. New fire extinguishers, gas alarms and an electric solenoid on the gas bottle were fitted inside the boat.
Our 10 man Zodiac liferaft last serviced in Sicily was 20 years old and no longer serviceable so a new 10 man raft was sourced locally. The container is much larger than the old one a deck mounting system had to be invented and installed. We continue to carry the old one as well.
Barb got busy on her new sewing machine and made a cover for the new liferaft, a new bag for the man overboard retrieval system, and also a bag for the heaving line quoit. Our safety equipment onboard is now up to date and current.
Barb can now say she used the sewing machine for real yacht jobs before she got distracted on other items, such as patchwork cushions and embroidery – see later blog. A special thanks to Sue at Country Dawn Quilting https://www.facebook.com/countrydawnquilting/who not only lent me a machine to do the first bag but has continually provided extra help and advice on all sorts of jobs.
Interior Upgrades
Eleuthera has large and comfortable beds with inner spring mattresses on wooden slats. The mattresses all needed replacing so we ordered new ones from Brownies in Auckland who came and measured up the beds and made us very comfortable new ones.
Somewhere in our travels the TV lifting mechanism had failed and needed replacing and the TV itself was not coping very well in the salt air environment on board. We obtained a new lifting mechanism and purchased a new Smart TV and with the assistance of a young German traveller onboard installed a much improved method of mounting the TV. With Starlink onboard Netflix, SKY Sport, YouTube etc are freely available wherever we go.
Starlink has become a basic necessity of cruising and we have upgraded our connection with Dishy now mounted with the new solar panels and the system is now powered from the DC side of the boat which reduces the power consumption by around 40%. Additionally we carry a whole other unit as a back up in case the one we have fails. We now use Starlink for navigation and communications when at sea and for all internet access when at anchor.
Such is the stability of large catamarans we had managed to sail perhaps 30,000 miles in Eleuthera with the microwave, coffee machine and toaster sitting on the bench with no restraints. However sailing to and from New Zealand proved to be a different matter and all of the above became prone to escaping. Needless to say we now have much more seaman like fiddles to contain these things in the future.
Saloon Lockers
The storage lockers under the seats in the saloon had always seemed a little suspect with some poor fibreglass repairs. After consulting Prevek the expert who had helped with the rudder bearings we decided to fix things properly. Hew spent a couple of days removing the water pump and cutting away the old repairs in preparation for Prevek to come and repair and reseal everything.
As this was going to be a dusty job and the water pump was removed. We organised for Prevek to come when we were going to be off the boat for a few days. Prevek was a very tidy worker, he carefully built a plastic tent over the work area, then sealing himself inside with grinders, sanders and the vacuum cleaner, he got to work. Unfortunately, the space he was working in had gaps into the rest of the boat. Having vacuumed everything up inside his tent, he emerged to find the rest of the interior covered in fibreglass dust, which took him a whole day to clean up.
Autohelm Redundancy
Eleuthera’s steering system is hydraulic with the wheel connected directly to a pump and below this in the system is an electric pump controlled by the autopilot. Normal cruising has the autopilot engaged +90% of the time.
The original pump failed while sailing from Tonga to New Zealand and we replaced this with a new pump as well as replacing the leaky manual bypass valves when we arrived in New Zealand. Expecting this to be long term solution we had the original pump rebuilt and carried it as a spare just in case there was a problem in the future.
Unfortunately, the new pump failed after less than 200 hours and on our abortive trip to French Polynesia https://kiwiflyingfish.com/2025/12/eleuthera-draws-parrot-fish-in-the-pacific-a-1500nm-voyage/ we had to make do with manual steering. While we carried a spare pump, it is not practical to try and change a pump at sea because the steering system has to be disconnected. Additionally, the original location of the pump made servicing or replacement very difficult.
Having had the new pump replaced under warranty we decided to install 2 pumps in parallel with the ability to switch between the them copying an installation on friends boat. Having 2 pumps plumbed in permanently gives built in redundancy and the process of changing between the two is a simple electrical switch. The pumps were also moved to a more accessible location and new hydraulic lines made to connect them up.
Dinghy Upgrades
Having been cruising for some years in locations with very small tidal ranges we were unprepared for New Zealand’s 2.5 metre tides. Our dinghy is a 4m aluminium rib with a 30hp outboard and while relatively light for its size still weighs around 200kg. With any less than 4 crew it is very difficult to drag it up or down a beach. It is great for dinghy docks, longer trips and as a dive tender but having been caught out a couple of times we needed a solution.
We now carry a second dinghy which with the outboard weighs less than 50kg and has fold down wheels. 3hp doesn’t go very fast but for shorter distances it is great and is easily dragged up the beach. When offshore the dingy deflates into a bag and the outboard goes into a locker.
While 30hp on a 4m dinghy may sound powerful it is a step down from our original tender which while much heavier had a 50hp outboard and would get on the plane pretty much regardless of the load. Not so the 30hp version so we are experimenting with different pitch propellors to try and improve performance in this area.
This gives you an overview of all our activities though
I am sure we have missed some out. For sure, there will be more in the future, but hopefully no big items in the short term. Not only do we need a rest, but our bank account does as well!!
Next Blog: Winter in Whangarei
