The Boat

S/Y Sundance

Maintenance and Gear Upgrade History

New Hydrovane self steering – 2023. (Install featured in SAIL Magazine, April 2024)

New Watt & Sea 600 hydrogenerator – 2023

Starlink satelite system – 2023. (Install Featured in SAIL Magazine, Feb 2024)

New Spectra Cape Horn 18 GPH water maker – 2021

New Yanmar 3JH40 diesel engine w/ new transmission – 2021

New built on engine oil change pump – 2021

Engine N2k network to RayMarine MFD – 2021

New propeller shaft – 2021

New cutlass bearing – 2021

New PSS shaft seal – 2021

New Max Prop – 2021

New engine shift and throttle cables – 2021

New custom 33 gallon aluminum fuel tank – 2021

New Maretron tank gauge system for fuel, and both water tanks – 2021

New fresh water system including all hose, faucets, pumps & filtration system – 2021

New North Sails fully battened mainsail with three reef points – 2022

(2017 North main kept as a spare.)

New North Sails 135 genoa – 2017

New North Sails 110 genoa – 2022

All new standing rigging and turnbuckles – 2019

New Harken roller furler – 2019

New LED masthead anchor/tricolor light – 2019

New steaming light – 2019

New VHF antenna – 2023

New Raymarine wind transducer – 2019

New Windex – 2019

All new mast wiring – 2019

New Edson leather spreader boots – 2019

New custom Forespar aluminum/carbon whisker pole w/ mast mount storage – 2019

New radar backstay mount – 2020

New Dynice Dux lifelines – 2024 (Featured in SAIL Magazine, June 2024)

Strip bottom paint, barrier coat and paint – 2020 (Project featured in Points East Magazine)

All new Ray Marine electronics:

• New Raymarine Axiom Pro Chatplotter/Radar display – 2019
• Dopler2 Radar – 2022
• Below decks autopilot – 2016. (Control head replaced 2023)
• New spare autopilot with all components – 2021
• 3@ i70s displays for depth, speed, wind – 2023
• New RayMarine AIS transceiver – 2024
• New Standard Horizon VHF/AIS w/cockpit remote – 2015

7 new 100 watt Sunwear solar panels – 3 @2017 / 2@2020 / 2 @ 2023

New house bank batteries: Lithium – 3 @ Battleborn 100AH – 2022

New engine start battery: Odyssey AGM Group 31 – 2023

New Victron battery monitor – 2020 (Install featured in SAIL Magazine)

New iPad at nav station for Victron display and Ray Marine MFD repeater. – 2020

New Viking 4-man RescYou Pro life raft – 2020

New ACR 406 PLB – 2015

2 new ACR 406 PLB/AIS – 2023

New ACR ditch bag – 2020

6 new inflatable life jackets / harness – 4 @ 2020 / 2 @ 2023

New flare kit – 2020

New Force 10 three burner stove/oven – 2019

New propane line from locker to stove – 2019

New Propane solenoid and regulator and sniffers. – 2019

5 new aluminum propane bottles – 2020/2022

Custom pushpit propane canvas storage sleeve for additional bottles above – 2022

New Manual bilge pump with all new hose – 2020

New electric bilge pump with all new hose and float switch – 2020

New high water alarm & pump complete w/ new hose and float switch – 2020

New steering cable and chain linkage – 2019. (New spare also stowed aboard)

New Sunbrella Bimini – 2016

New Sunbrella dodger with new fly to Bimini – 2020

New canvas pedestal cover – 2016

New custom oar storage bag for both primary and back-up oars – 2022

New forward hatch rain fly – 2019 (Featured in SAIL Magazine – December 2023)

New SeaFrost DC refrigeration system – 2016

New running rigging – 2016/2020/2023

• Main halyard
• Genoa halyard
• Spin halyard x 2
• Main sheet
• Jib sheets
• Jib car control lines
• Traveller control lines
• Roller furling
• Boom vang
• Topping lift
• Reefing lines

New anchor chain – 180’ of 5/6’’ G4 – 2022

New anchor – Rochna 25 (55lb) – 2022

Replace cockpit scupper drain deck fitting elbows – 2022

New Harken traveller car – 2022

New hot and cold cockpit shower – 2023

New paper charts for entire East Coast plus  Bahamas plus Bermuda & Azores – 2022

New Navionics chart chips for US East Coast, Caribbean, Azores, Western Europe, Scandinavia – 2022 – 2025

New C-map chart chip for Bahamas – 2022

Three new regular use fenders and fender covers – 2023

Three new jumbo inflatable fenders – 2024

New sink and counter top in head – 2020

New rain water collection system – 2020 (featured in SAIL magazine – May 2023)

New custom knife block with hidden magnet – 2020 (Featured in Good Old Boat magazine)

New mainsheet blocks – 2020

New custom drawer for tools at nav station – 2020

New cutting board for galley sink cap – 2020 (Featured in Good Old Boat Magazine)

New custom toilet pump handle – 2020 (Featured in Good Old Boat Magazine)

New Cassen & Plath Horizon Ultra Sextant – 2018

New toilet – 2018

All new head hoses and Y-valve – 2018

New Bomar overhead opening hatch in salon and fwd stateroom – 2018

New engine raw water intake hose and clamps and sea strainer – 2018

New Jonbouy man overboard inflatable horseshoe and pole – 2018

New cockpit drain hoses – 2019

Custom teak helm step – 2017

Custom Companionway seat for watch keeping in wet/cold weather. In the Navy they say only admirals and assholes stand in the companionway, so I figured I aught to sit down. – 2022

New LED running lights – 2025

New fire extinguishers – 2017

New anchor windlass – 2023. (Complete spare also aboard – new 2024)

New cabin lights in fwd state room – 2017

New handheld VHF – 2016

New handheld GPS – 2016

New Weems and Plath clock & barometer – 2015

New Edson single lever engine shifter – 2015

New wheel leather and dodger grab bar leather – 2015, 2023

New engine driven cabin heater – 2015 (featured in SAIL magazine – May 2023)

New salt water washdown pump, hoses and sea strainer – 2015

Rebed deck prisms – 2015 (featured in SAIL magazine – May 2023)

Rebed side deck scuppers – 2015

Rebed chain plates – 2015/2024

Rebed teak grabrails  (Grabrails stripped and varnished off the boat) – 2015

All exterior teak stipped and refinished with 4 coats of Cetol topped with 4 coats of Epifanes.  – 2015

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Routine maintenance:

Prep and apply 2 coats of exterior varnish every 6 months

Change engine oil and filter every 250 hrs

Change fuel filters every 500 hrs

Change engine raw water pump impeller every 500 hrs

Change Max-Prop zinc every 2 months

Regular interior and exterior cleaning

Service winches, prop and steering system once a year

Hard sand prep and apply 2 coats of Interlux Micron CSC bottom paint once a year

Diver to scrub bottom once between annual haulouts for paint

Wax boat every 6 months (Topsides, smooth parts of cockpit, house and deck)

Varnish cabin sole every other year

Replace sails every 20K miles

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A Spare Parts List

Breaking Down The Art of Breaking Down

“‘We must all suffer from one of two pains:

The pain of discipline or the pain of regret.

The difference is discipline weighs ounces while regret weighs tons.”

– Jim Rohn

A good onboard inventory of spare parts is a treasure chest. It’s like having your own custom-built marine store at arm’s reach at all times. Spare parts make crucial repairs possible and are essential equipment to carry. Experienced sailors cherish their spares and will happily make space for them aboard at the cost of room for other important things like surplus food and extra crew. You’re going to need most everything on the spares list eventually, so the expense is justifiable. Wisely purchasing ahead is good seamanship.

Spare parts lists should be customized to match the boat. The list below serves as a good generic starting point:

Recommended Spare Parts Inventory

Numbers refer to storage location on the boat storage map.

In no particular order, because you never know which spare you’ll need next.

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Spare plumbing parts:

– Electric bilge pumps – 12

– Electric bilge pump float switches – 12

– Manual bilge pump – S&M

– Manual bilge pump service kit – 13

– Electric freshwater pump – 13

– Freshwater and saltwater foot pumps – 7

– Saltwater washdown pump – 12

– Saltwater washdown hose quick disconnect fitting – 11

– Toilet rebuild kit – 7

– Toilet pump – complete – 7

– Toilet pump handle – 7

– Toilet holding tank macerator pump – S&M

– Water heater heating element and thermostat – N/A

– Watermaker service kit – 16

– Watermaker filters – 16

– Watermaker pressure pumps – 16

– Replacement seacock handle – N/A

– Assorted stainless hose clamps of relevant sizes – 12

– Miscellaneous rubber O-ring kit – 11

– Assorted lengths of relevant hose – 41

Spare engine parts:

– Propeller – S&M

– Starter motor – S&M

– Alternator – S&M

– 3 @ raw water pump impeller and gasket – 25

– Raw water pump – complete – 25

– Shift cable – 15

– Throttle cable – 15

– Replacement electric stop solenoid – NA

– Belts – 25

– Replacement dripless packing lip-seal – 25

– Replacement stuffing box flax packing – N/A

– 3 @ engine oil filters – 25

– 6 @ engine primary fuel filters – 25

– 6 @ engine secondary fuel filters – 25

– Engine oil. (Enough for two changes.) – 40

– Transmission oil. (Enough for two changes.) – 40

– Engine coolant. (Enough for two changes.) – 40

– Engine oil change pump – S&M

– 6@ sacrificial zinc anode set – 39

– Diesel fuel – 44

– Diesel fuel transfer pump – 11

Note:

– The generator, if you have one, requires most of the same spare parts as the engine. 

– The dinghy motor, if you have one, requires many of the same spare parts as the engine.

– Twin-engine boats need not double up on all engine spares.

Spare electrical parts:

• Navigational electronics:
  • Autopilot – 43
  • Chartplotter/MFD – S&M
  • Cartography chips for above – S&M
  • GPS antenna – S&M
  • Depth/speed/wind display – S&M
  • Depth/speed/wind transducers  – 5 and S&M
  • VHF – S&M
  • AIS – S&M
  • VHF antenna – 36
  • All network wiring components of the system – 13

– Handheld GPS – 35

– Handheld VHF – 35

– Solar and hydro-generator charge controllers -12 

– Solar and hydro-generator system spares – 12

– Anchor windlass – complete with all associated parts – 1

– Propane solenoid – 12

– Propane regulator – 12

– Propane sniffer – 12

– Replacement light bulbs – 14

– Running lights – 13

– Replacement fuses – 37

– Replacement panel breakers – 37

– Miscellaneous lengths of relevant wire – 37

– Miscellaneous wire connectors and end fittings – 37

– Heat shrink tubing – 37

– Wire ties in various lengths – 37

– Phone/tablet/computer chargers – 25

– Phone /tablet/computer charging cords – 25

– Favorite phone apps on alternate devices – Yes

Miscellaneous spares:

– Steering system spare parts kit per manufacturer’s recommendation – 15

– Emergency tiller – 40

– Windvane steering system spares kit per manufacturer’s recommendation – 11

– Running rigging: all halyards, sheets, and control lines. – 41

– Emergency replacement stay. (Customizable dux is best for this job.) – S&M

– Blocks, shackles, cotter pins of relevant size and design – 14

– Deck plate cap compatible with fuel, water, and waste fills – N/A

– Deck plate cap O-ring for above – 11

– Deck plate key for above – 34

– Winch handle – 41

– Winch spare parts kit – 14

– Crucial tools – 34

– Miscellaneous stainless fasteners – 36

– Opening port gasket material and replacement hardware – 11

– Cooking stove/oven spare parts kit – 12

– Galley essentials – 33

– Dock lines – 41

– Chafe gear – 11

– Anchor chain snubber line hook – 14

– Oar locks – 13

– Oars – 46

– Reading glasses – 25

– Sunglasses – 25

– Miscellaneous disposable batteries – 26

– Fire (matches) – 26

– Drinking water (1 gal/crew/day) – W

– Hat – 2

Yes, this is a long list. And no, not even I, its author, stock all of the above spares on my 36-foot cruising boat. In some cases, an item is not applicable to my boat, but I felt compelled to include it for the purposes of this general discussion. I’ve noted these items as “N/A” in the list above. (In some cases, “N/A” also stands for not available. The outcome is the same, so I didn’t bother with a different acronym.) The careful reader will also note that several items are listed as “S&M.” It’s not what you think! In this case, the acronym stands for “storage and money.” As in, if I had more storage space and/or more money, I would add this item to my spare parts inventory because I think it is worthy of inclusion. As is the case with all dogma, use your best judgment when you work out your own list for your own boat.

Smart Storage

With so many parts and supplies stowed on a boat, it can be hard to find the part you need when you need it without some well-thought-out organization. Maintaining a storage map for your boat will help you lay hands on parts when needed. A checklist of parts will help with inventory. The numbers following the parts on list above indicate the location on the storage map for my boat.

Some practical logic is worth considering when thinking about spares. Opting to stow a spare part near where it will ultimately be put into service is smart storage. Triple-plastic-bagging is smart storage. Stowing heavy things low and amidships is smart storage and good seamanship. Soft-sided storage bags, especially parachute bags, deliver both compact and flexible packing that tends to maximize the use of unusually shaped storage spaces. 

For ease of installation, spare parts should be identical to the parts currently in service aboard the boat. When you use a spare, don’t forget to replace it in the inventory at a the next convenient and cost-effective opportunity. For installation of most spare parts, you will need tools. Oftentimes, sealants, adhesives, and lubricants will also be required.  We’ll save the review of those supply lists for another discussion.

Obsolescence

Obsolescence provides a compelling argument for stocking spares. Nowhere is that more true than in the quickly evolving world of marine electronics. New equipment on your boat today is likely to be outdated in three years, and many replacement parts may no longer be available then. Likewise, a replacement component purchased three years from now is not likely to be compatible with the rest of the networked system you currently have installed aboard.


I was recently tasked with repairing an autopilot system on a sailboat. Troubleshooting led me to conclude that the box containing the central computing brain in the system had failed beyond repair. That component, although only a few years old, was obsolete and no longer available from the manufacturer or anywhere online, new or used. The updated replacement component from the manufacturer was not compatible with all the other older parts that plugged into it: the drive unit, compass, rudder angle indicator, and control head. The only solution was to replace the entire autopilot system. The new drive unit required engineering and construction of a new mount. The new generation of communication cable used by the new autopilot was incompatible with the networked chart plotter, necessitating the replacement of that screen as well. Once renewed, the chart plotter was no longer compatible with the existing radar or the wind, speed, and depth instruments. At the end of the project, the VHF radio was the only component in that boat’s electronics system that didn’t demand renewal as this project snowballed. (But it did require a software update.) None of the electronics on this boat were exceptionally old, but to maintain full functionality, I needed to replace almost everything because of one failed component. 


For compatibility’s sake, it’s wise to equip a boat with the same generation of electronics built by one manufacturer. When renewing a suite of electronics, it’s prudent to purchase spares for every component and every cable in the system. Spare electronics are also excellent to have on hand for troubleshooting tasks.


Marine electronics are expensive, but installation engineering, wiring, and installation labor is considerably more costly. Opportunity costs associated with a mid-season breakdown are the highest of all. If you conclude that you need a piece of electronic equipment on board, then you need spares for all components in the networked system.


In today’s age, phone apps are ever more relevant onboard, and as such, ever more worthy of backing up with a spare. The prudent mariner will load all favorite weather, navigation, satellite phone, cruising guides, and other relevant apps, complete with subscriptions as needed, onto another device aboard, such as a tablet or a regular crew member’s phone. This way if the boat’s primary navigation phone is lost, stolen, or sunk, functionality aboard won’t skip a beat while waiting for that lost phone to be replaced.

Different spares for different ships

Sailors use their boats in different ways, and the onboard inventory of spare parts should be adjusted accordingly:

– The day-sailor’s need for spare parts is negligible, aside from a spare hat should one get lost over the side. This boat is always close to home, where parts should be relatively easily sourced as needed. Considerations for obsolescence is a noteworthy exception.

– The coastal cruiser is well advised to store a full complement of spare parts aboard. Having the right spare aboard to enable the timely repair of a crucial system while at sea is an important safety factor for the near-coastal boat. If you can limp into port with a broken gear, stocking spares is still a valuable practice. When a component fails during your mid-summer cruise, sourcing that part will become your first project, or your local mechanic’s first task. Inevitably, it will be a Friday afternoon, and your replacement part won’t arrive until Tuesday at the earliest. Having the spare part already aboard will save you a long delay and an expensive second trip to the boat for the mechanic, if you opt to hire one. Also, a planned purchase in advance, without express shipping, will be less expensive than rushing the part to the boat when it’s suddenly needed.

– The ocean-crossing boat must carry all her spare parts despite the competing demands for storage space aboard such a boat. Because self-sufficiency is mandatory in the middle of the ocean, the crew of this boat should possess the tools and knowledge required to install all the spare equipment. If the crew lacks the strength or skills to replace all the components of the boat’s systems while at sea, they needn’t give up their dream of crossing an ocean. Instead, they should opt to cross an ocean in a simpler boat.

– The captain of the near-coastal race boat, obsessed with minimizing weight, may take a “damn the torpedoes” attitude and opt to stow many of their spares on the shelf in the chandlery. The offshore race boat, on the other hand, should value self-sufficiency and carry most recommended spares aboard despite the weight.

When buying or selling a used boat, a proper inventory of spare parts should be expected as a part of the transaction. An inadequate supply of spares should be a red flag for any buyer and make them question where else the seller has cut corners in regard to boat care.

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S/Y Sundance – Fuel Chart

Fuel capacity:  33 Gal.  Conservative Range @ .8 gal/hr:  41 hrs or 246 miles @ 6 knots

Yanmar 3JH40  Eng. #: E10755  Transmission: KM35A2 Ratio: 2.64:1

Engine oil: Shell Rotella-T 15W40   Transmission fluid: Straight 30 weight engine oil

 Oil filter: Yanmar: 119305-35170  

Fuel filter:  Prime: 121857-55710-2    Secondary: 129A00-55800-HD

Impeller: 129670-42610  Belt: 129675-42280

Mack Boring: (908) 964-0700

Date

Old engine: 2014 – 2020:  1026.5 Hours   691.3 Gallons of diesel           .67 Gal/Hr.

New Yanmar 3JH40 engine installed 2021. Install also included new engine bed, oil change pump, N2K link from engine to plotter, new fuel tank, new primary Racor filer, all new fuel lines, new muffler and all new exhaust hose, new shift and throttle cables (and a spare set), new prop shaft, new 3-blade feathering Maxprop, and new cutlass bearing.

2021: 202.9 Hours 119.6 Gallons of diesel .59 Gal/Hr

2022: 469.6 Hours 336.8 Gallons of diesel .72 Gal/Hr

2023: 812.6 Hours 546.1 Gallons of diesel .67 Gal/Hr

2024: 210.3 Hours 125.2 Gallons of diesel .60 Gal/Hr

Engine hours as of Jan. 1, 2025: 1730.7

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S/Y Sundance 

Storage Plan 

1. Aft hanging locker 

Small hand tools 

Dewalt drill and saw 

Fasteners

Misc. electrical supplies 

Sealants

Lubricants

Refrigerant supplies and tools 

Sewing kit 

Ditch bag (Passports, EPIRB, VHF)

Anchor bag

Foul weather gear

2. In Chart table 

Batteries

Computers

Ships papers

Pens/pencils

Eye glasses / Sun glasses

3. Under Chart table 

Engine filters, supplies & spares 

4. Under Galley sink 

Water filter spares 

Filter wrenches 

Dish towels

Spare dish and hand soap

5. Low between engine and aft hanging locker 

Dorade caps 

Prop & hull zincs 

Max Prop spares

Wooden plugs 

6. Under Port Settee 

Rule 800 Bilge pumps
Rule Super Switch float switch
Toilet rebuild kit
Toilet pump – complete
Propane solenoid, regulator & controller Windlass controller & Solenoid
Battery Switch

Solar panel plugs
Oar locks & garboard plug for tender Boarding ladder stand-off pads 

Manual bilge pump rebuild kit

Steering cable/chain linkage Misc. 

RayMarine cables 

Barient winch parts

Blocks of wood

Solar panel regulator

Elec. & foot fresh water pumps

Running lights

7. Under Stb Settee 

Water maker spares and parts 

Shift & throttle cables 

Bungs

Replacement faucets

Misc. small parts – bulbs, etc.

Misc. plumbing supplies 

Hose clamps

Force 10 stove spares 

O-rings and rubber gasket supplies

8. Outboard of stb settee seat backs 

Aft: Paint locker: Varnish & sandpaper, etc.

Fwd: Life Jackets & Harness tethers

9. Outboard of port settee seat backs 

Aft: food

Fwd: blankets

10. Salon stb fwd locker

AC Heater

Flags

Lead line

Flare kit

11. Salon stb aft locker

Dog food & supplies

Vacuum

Dinghy cable lock & oar clamp

12. Salon port fwd locker

Placemats and napkins

Screens

Candles

13. Salon port aft locker

Food

14. Outboard of toilet in head 

Spare toilet pump & spare handle

Spare foot pump

1st Aid Kit

15. Below floorboard in fwd cabin 

Spare Depth/Speed/Temp transducer 

16. Below seat in fwd cabin 

Behind seat-back: sockets and wrenches

Below seat: large hand tools

17. V-berth footwell port low 

Extra cleaning supplies & trash bags

18. V-berth footwell stb. low 

Rain boots

19. Below V-berth fwd. low 

Spare anchor windlass

20. Aft cockpit locker 

Dock lines

Spare lines

Spare hose

21. Port cockpit locker 

Spinnaker

Fender board

Scrub brush

Scuba

22. Stb cockpit locker 

Cockpit seat and cushions

Swing seat

Wine & beer

Fenders

23. Under autopilot at steering quadrant

Spare Autopilot