Publish Date: Tuesday, June 2, 2009
Location: Sandusky, Ohio
Coordinates: 41° 28.795′ N 82° 41.157′ W
You may have read of our flybridge shift cable problems in an earlier blog. After replacing the broken cable, we were left with the same problem that led to the eventual failure: A very tight control cable resulting in difficult operation. I was not happy, and I knew I had to figure out a better solution.
I decided to consult with both Nordhavn and the Nordhavn 43 Owners Group — I couldn’t be the only owner with this problem. A couple other N43 owners had had the same problem, and they solved it in a few different ways. The list of possibilities that I gathered boiled down to these:
- Install an “industrial strength” control cable that would not fatigue as easily. I wasn’t crazy about this idea alone because it would not improve the difficult operation (although it would probably prevent another failure).
- Try to simplify the complexity of the cable run so that it would operate more easily. One owner spent quite a bit of time on this, and it resulted in significantly better operation, so I liked this idea.
- Install dual control transfer units, which would remove the master/subordinate relationship between the flybridge and the pilothouse controls. This seemed like a good idea to me too, but it would require me to replace all the cables for both controls, which would be both costly and inconvenient.
- Replace the whole system with electronic controls. This is the most expensive option, but it would also result in the smoothest operation, and it would provide some improved functionality. Maybe eventually.
I decided to take an incremental approach to solving the problem, hoping to change as little as possible to improve the situation. I planned to install an industrial strength cable, and also work on straightening the cable run.
The industrial strength cable is larger than the regular control cables, and most marine stores don’t have them in stock. While I was ordering one, Jim from Anchor Marine in Erie, Pennsylvania asked me if I had tried Teleflex Supreme cables in the normal size. They are lined with silicone, and he had several customers who had great results with difficult cable runs. I decided this was worth a try.
Before installing this new cable, however, I also wanted to see if I could simplify (i.e., straighten) the cable run. I pulled off all the dashboard panels and ceiling panels so I could see the entire route. All in all, it wasn’t too bad, but there was one spot that had a tight “S-curve”; I suspected this segment was causing most of problem. It was where the cable came down through the wiring tube between the flybridge floor and the pilothouse ceiling, and then had to jog back up and forward to run down the center channel of the windshild. It looked to me like I could drill one hole in the pilothouse ceiling that would allow the cable to flow smoothly in a long curving arc between the top of the windshield and the flybridge control. The new hole would be just forward of the wiring tube, and it would be angled to follow the natural curve of the cable.
I have to admit that I was a little hesitant about drilling a hole in our beloved boat. If my idea didn’t work, I would have a new hole that was unnecessary. Worse, what if I mis-judged something, and ended up damaging something else that would need to be repaired? My Dad always told me, “measure twice, and cut once”, which is good advice for any engineering project. I spent quite a bit of time agonizing over the location and angle of the new hole, but eventually I put drill to fiberglass, and let ‘er rip!
I’m pleased to report that our new cable installation works GREAT! The new hole allows the cable to follow a gentle large-radius curve from the windshield to the pilothouse control. The Teleflex Supreme cable has a very smooth and easy feel to it. The flybridge shift control is now as easy to operate as the pilothouse control, and I have increased confidence in the whole system. I’m not sure which part of my fix was more impactful, but I’m pretty sure both parts contributed significantly. Thanks go to the Nordhavn 43 owners and Jim at Anchor Marine for helping me solve the problem.
On to the next project!