Gato build has resumed.

[Ralph --- SSBN 598]

Went out to the shop to check on the glue progress.
Solid as a rock.
You might think I could go on but I don't think so.
Opened the door to the shop to be hit in the face with 113 F.
Checked outside temp in shade and sure enough, the cool weather did not show up today.
Hoping for tomorrow.

Still meeting my 10 minute minimum per day do something to keep the project moving forward.

[Ralph --- SSBN 598]

August 7th ======================

I was not in the shop yesterday.
Stopped at the post office because I had gotten 2 e-mail messages saying my orders were delivered.
I ordered servos on July 28th and batteries on August 3rd.
The batteries where USA local (about 60 miles away)
The servos said they were coming from China but I think they have a USA warehouse somewhere.

Unpacked the servos.
All look like the web page.
Info on packages is correct for what I ordered.

Now for the disaster part of this.
Unpacked the batteries.
Individual boxes.
Inside more plastic bubble wrap packaging.
So much clear tape.
I got the first 2 out and every thing is find.
The third battery was not so lucky.
While cutting the tape, it appears I also got one of the two power plug wires.
A quick sparking flash and a little smoke.
Finish unwrapping the battery and found the wires were not cut but the insulation was missing for about 1/2" on both wires.

Also my scissors have a nice 1/4" notch in the middle of the blades. I ground and sanded the scissors and they are now dedicated shop scissors.

I looked over the battery and between two cells has separated.
I tested the voltage and found it to be correct.
I tried soldering the tabs back together.
No luck.
I will keep this battery and think of some how making a tray for it.

I have 6 good batteries.
So with 3 Tx I have one for each and a backup for each.
----------
On to the boat.
A problem I have had for some time is room for the power wires.
They barely fit through the brass tube going through the ballast tank with the 2 servo wires.
I made straight inline brass tube connectors which work well but when they go under the electronics trays, they tend to life the tray slightly.

Before I left the shop on Thursday, I decide to make small connectors.
The original connectors had 1/8" tube plugs going in to large brass tubes.

Today, I made the new connectors and installed them.

The new connectors have 1/16" brass rod that goes in to a 3/32" brass tube.
The new connectors are much smaller in physical size.
I ran current test before starting on the smaller wires I have.
They are the same size as the wires that came on the new motors.
Ran at full throttle and with the air pumps.
After 5 minutes I touched the wires and they are not even warm.
I do not run my boats at full throttle and I actually have them programed at the Tx down to 40%.

In the cylinder the new connectors leave a clearance of about 1/8".
That's it for today.

[Ralph --- SSBN 598]

August 7th ======================

Today started with trying to stuff both electronics trays in to the cylinder.
Pulled the new power wires through the ballast tank through tube.
Plugged everything in and tested.
Of course I had to change the bow plane servos because they were reversed.

Slid the rear electronics tray in while pulling the servo and power wires through the ballast tank tube.
No problems at all.

Move to the front tray.
It slides in easily but then all the excess wires started bunching up.
I turned the tray and got move to the wires to bundle up behind the tray.

Now of course there is a problem.
The rear tray is all the way in the cylinder but the tray is not sitting level.
Something is holding the back end up about 1/4".
Took it out and slid the tray in to my short test cylinder.
The tray still is not level but I can look down the cylinder from the back end.
With a long screw drive I moved wires around but they all seem to be loose and not touching the cylinder.
So I used the screw drive and pushed down on the electronics tray at the back.
I could see the tray rocking up and down a little.
Looking through the side, I looked for the fulcrum point.

There it is!
The 2 small battery plugs which are under the battery tray where touching the tray and the cylinder wall.
Took the tray out part way and stuffed the 2 plugs to the side of the tray where there is more room.
Slid the tray back in to the test cylinder.
This is the problem because the tray slid in all the way and sits level with no effort.

Okay take the tray out and see if I can re route the wires to the plugs so the plugs are in front of the battery tray.
1 plug makes it there but the other one does not.
Needs about 1/2" more wire in length.

Took the tray out and removed the power switch which the 2 plugs are soldered to.

Found a new plug with the original 8" of wires still on it.
Unsolder the original plug and soldered in the new plug.

Plugged the batteries in to their plugs and taped the plugs in front the battery tray, under the power switch.
Also taped down the 2 battery charging balancing wires and plugs.

Checked the tray in the test cylinder.
It dropped right in.

Next is to plug in the 2 servo extensions and power wires.
Put the tray in the cylinder and see if it slides in all the way.

It does and then I tested the system.

Everything works.
Rudder, rear planes, main motor, bow plane retract, bow plane pitch and ballast tank air pump.
Everything works.

Then I thought, I have never tested the Lost Signal Fail Safe which should move the bow planes to full rise.
Well the Fail Safe works but I have full retracted bow plane servo.

Pull the tray out of the cylinder and trace the 2 servo wires that are now taped in place.
Reversed the 2 servo plugs.

All is good now.
I can put the tray in the cylinder.

I need to reinstall the gear box with the o-ring pressure plate.
Then the 2 safety cables.

I have run out of time for today.
I will go out and make sure all the power is off on the Tx and Rx.

Later this evening after the sun goes down and temp drops abut 20 to 30 degrees, I will see about filling the water test tank.
Maybe water test the cylinder tomorrow.

[Ralph --- SSBN 598]

August 9th ======================

All the electronics are in the cylinder.
I have used the fuel hose to blow pressure in to the cylinder and all seems to be leak free.
This is promising.

But then this build has been a nightmare of broken parts and other progress stopping issues.

Testing the system on the bent before putting in to the water test tank, I find that only the secondary air pump activates.
I looked and looked through the cylinder wall and could not find anything wrong.

So, I have to remove the front tray to pull the wires through to get the rear tray out of the cylinder.
Done.
This is become an easier and easier jog do to lots of practice.

Now looking at the 2 micro switches that operate the air pumps individually, the number one switch lever looks odd.
I touch it with a small screw drive to activate it and the metal arm that push the switch button falls off.
I look through my parts boxes and I find no more switches.
I find the empty package but no switches.

I got to try different brand f switches.
These do not hold up to modifying the lever angle.
The stainless level is bent at 90 degrees coming out of the switch body and it must be stressed right to it's failing point.

Did a search and found some switches that have the same measurements and made by different maker.
Okay switch issue taken care of.
I think I will continue with the cylinder leak testing. (I don't need both air pumps to do this)

The testing will continue tomorrow.
Got real stuff to do this afternoon.

I have been working on they cylinder system so long, I noticed that the 2 little screws that hold the deck on the hull are not where I put them so many months ago.
I think I will move the hull off the bench and do a full search with a flashlight.
The screws are like other screws but they were shortened and they are painted dark gray on top to match the deck paint.

These are screws that were heated and then turned in to the plastic to make threads.

Working on the George Washington modification is looking better and better.

[Ralph --- SSBN 598]

August 11th ======================

I have been doing other stuff I got to thinking that I have gone through a lot of micro switches trying t make this work.
I have more coming next week but I was thinking maybe I should try making a brass slider contact unit.
I only need a power wire and 2 contact sliders.
1 for each pump.

So this morning before getting started on other stuff, I cut plastic pieces and glued them together.
I will let them cure and then turn them to fit in to a small brass tube. I think it's 1/4" but not sure.
Then make 2 piano wire contacts that will slide on the brass tube and plastic piece.

The piano wires will be it's own spring to hold contact on the brass tube.
I have cut the brass tube to length and just waiting to finish the plastic piece.

Off to do more other stuff.

[Ralph --- SSBN 598]

August 14th ======================

Thought I would check in.
Progress is being made on the Gato.
The issue is the heat.
I try to get out to the shop early in the morning.
But by 9am it is passing 100F in the shop.
Getting old and I can not take the heat any more.

I have been working on a switch for my air pumps.
The ones I bought all failed in some way.
The metal lever breaks off.
The inside contacts stop snapping and stop making contact.
I have gone through several switches.
I order from another manufacture and the will be here this next week.
But I thought I would try to make a brass sliding switch.
I have been cutting plastic and gluing it together.
This has been as slow process.
It is coming along thought.

Anyway, I just wanted everyone to know work is moving along even though I have not been posting it.

[Ralph --- SSBN 598]

Checked the thermometer on the front porch.
Looks like 109F at 12:42pm.

[Ralph --- SSBN 598]

August 14th ======================

Real life has gotten in the way again.
Have not been out in to the shop.
The switch I am making is coming along but very slowly.

Today, at the post office was a package of new switches.
Will see if they will do the job.
But I may not get to it until next week.
I received several appointments at the VA.
Looks like they are going to do follow up surgeries on my wrist, side of neck and maybe my forehead, again.

I don't have a problem with these surgeries.
They just take up time.
88 miles to the hospital and a couple of days in bandages.

[Ralph --- SSBN 598]

August 18th ======================

I am considering taking up watching grass grow.

Today, I got the ballast tank switches installed and working.

But this was not the fun part.
After installing the switches and control rod, I hooked up the Cylinder system and proceeded to test everything.
I got as far as turning on the power switch in the cylinder.
Immediately there is smoke.
Pulled the battery plugs to disconnect from system.

Looked for problem.
The Speed Controller was hot to the point the plastic plugs melted.
Removed the speed controller from the electronics tray.
Checked with multi meter.
There appears to be a short in the speed controller.

I checked the other equipment and found no shorts.

Dug through parts box and got a 2 wire servo wire for the battery to Rx.
Turned on system with no speed controller and all servos work.
Next I checked the ballast tank control rod and switches.
Only need to adjust the center off position then check that the control rod turns on both switch in order and shut off at center.
All is now good.

I think I have spare speed control of the same brand.

I notice I need to make a new set of wires for battery to power switch.
These are a bit stiff now.

Set everything on the bench because I have VA stuff to do today and tomorrow.

Well, it is not over yet.
Put the Tx on the other bench where it is out of the way.
As I turned around I hear a load noise.
Looked back where the Tx is and there is a large wrench from the shelf above the bench.
Tx looks ok.
Tried all the controls.
Yep, a direct hit on the B toggle switch.
It no longer moves.
Opened the Tx case and found small switch parts loose in the case.
Now I am searching for a replacement switch.
I can use the Tx as is because I don't use the "B" switch but I do not like the hole in the case.

I am thinking seriously about watching grass ground.
Here in the desert, that is about a 3 week time period just after winter and before summer kills all living grass and small plants.

I think I will make an eight foot by eight foot 2x4 box on the ground to plant the grass in.
I got enough wild rabbits to not have to mow any of it.

[Ralph --- SSBN 598]

August 28th ======================

Yesterday I received the new smaller power plugs.
They are much smaller than the ones I have been using.
I think they will fit.

I hope to get in to the shop tomorrow for a little while.

This past week and a half has not been going in my favor.
Surgery on neck went well.
The healing has not gone well.
Today I was suppose to get stitches out but do to infection, it will be next week.
Instead the doctor cut on my eye lid in the corner next to my nose.

Got some heavy duty antibiotics to take for a week..

Got 10 sites froze. Arms and neck and forehead.
I am thinking I am a training aid for new doctors.

Also yesterday, my car decided to let me down in town.
Would not start.
The battery seems to not keep a charge.
Friend brought jumper cables and the car is at home.

Thank goodness for AAA.
They have battery service.
Guy showed up in 40 minutes. (I live 11 minuites from town)
He tested the battery, and starting systems.
As well as the alternator.

HE found the battery was not fully charged.
We agreed I would charge the battery disconnected from the car, over night.
Then hook up cables and see if the battery drains again.

The tech guy also said if the battery drains, he will come back and replace it with new.

I sure Like my little 1986 Toyota pickup.
It has never let me down in 35 years and about 250,000 miles.'
I have had 5 of these trucks and sell them at 400,000 miles.
They just keep going.

My plan is to get the new plugs in the boat and get the system up and running.
Then in to the water for leak testing.

I know all the controls worked before I took the system apart to enlarge the ballast tank.

I might have this boat running for the gathering of SubRonLA on Sept 10th.

[Ralph --- SSBN 598]

September 1st ======================

The past two weeks have not gone well.

The car is still not working right.

The alternator is doing it's job according to the test AAA did on the car.
I have tested the battery out of the car and it will take a change and it held it for 5 days on the wooden work bench.

Put the battery back in the car and the car started up on first try.
Let the car sit over night and the next day there is not enough battery to turn the starter motor.
When hooking up the battery cables, I see a good spark.
There is something not turning off when the car is turned off.
This is not something I can trace on a 2016 car.
Too much electronics.

Next issue. 2 weeks ago I went to VA for 3 appointments on the same day.
Two were surgeries and one was testing on eyes.
Good news was I thought one surgery was going to be third on my wrist. Turns out, they already did the third, going two on same day 3 months ago.

First surgery was on my neck.
Was from just under my right ear down my neck 4.5".
Second surgery didn't happen.

They eye testing was for peripheral vision.

A week later I go in to have stitches removed.
This was not done.
The area had become infected and they could not take out stitches because the swelling might tear open the original surgery cut.

No matter.
They decided to biopsy my left eye lid.
And they gave me some heavy duty antibiotics to take.

So as far as working in t shop, it has not been a priority.

I did get all the wiring completed this morning.
Smaller power wires to go through the ballast tank through tube.
Smaller power plugs which all fit in the limited space I have.

Next will be to trace all the wires to make sure I did not cross something up.

Then clean up the o-rings and grooves to regrease.

I hope to get in the test tank water in a day or two.

I am just not 100% yet.
Another trip to VA this Friday.

Not sure what I will do with the car.
Maybe charge the battery and take a second battery with cables in case they are need.
Take the car to the dealer and let them fix it.

[Ralph --- SSBN 598]

September 5th ======================

The stitches are out.
The infection is almost gone.
Feeling better.

In the shop for a little while.
I was checking the wiring from batteries to motor and other electronics.
Well, I must have not been feeling my best as I got 4 main power connectors reverse.
All the plugs will not connect correctly.

I sat down and slowly removed the soldered plugs and chenged them as I went.
Checked again and I think I got them corrected.

Now to program the new speed controller.
That went well after I remembered to plug it in to the Rx.

This speed controller is a Robbe unit.
It is made so there is 100% froward and 50% reverse once set.

Well, I got the 100% forwards but it looks like less than 25% reverse.
Tried reprogramming a couple of times with the same results.
I removed the gear box thinking it might be putting too much force or friction on the main shaft.
Did not help.

I do not think reverse at 25% will be effective except from a stopped position.

I am going to rethink this speed controller.
I have others I can use to test with but they are too big in physical size to put in the boat.

I did remove a brass tube bushing from the gear box for the main motor shaft and the shaft is now supported by the end cap bushing.
Not a problem.
--------------------
As I was leaving the shop, I did not notice the visitor.
Too bad because it got it's head closed in the door and was killed.
I would have taken it out back because this was a good guy.
4.5'

[Ralph --- SSBN 598]

October 3rd ======================

It has been a month since I updated this thread.

A lot has happened.
I will start with the car.
I charged and test tested the battery out of the car on a wooden table.
I left it there for 5 days.
Put it in the car and the car started up. on first try.
Next morning the battery did not have enough power to turn the starter motor.
I did this 3 times.

I scheduled the car in to the dealer to find out what was wrong and get it fix.
Their schedule was so crowded I could not get in until the 29th of Sept.
Got up early and put the battery of quick charge.
Hooked it up after 20 minutes and started the car. Removed the charger and off I went to the dealer.
I did not turn car off at the dealer.
The service guy got to me, was first in line, and he did his check in the turned off the car. It started right up. Turned it off and then nothing.
He tried a couple more times.
Off he went to the service garage and came back with a tester for the battery.
The readings he got where very interesting.
The battery is a 850 amp and his readings were 65 and 67 amps.
He tried starting the car again and now the battery read less then 5 amps available.
The battery is shorting out in a cell.
But then it isn't.

The possible answer is something is between two plates and is moving.
Some times not touching and other times shorting out between plates.

They could not do any other testing of the electrical system until the battery is replaced.
I came home and took my battery to AAA service center and got a new one.
It took longer than I expected to get a new battery until I realized the guy was trying to warranty the battery exchange. I told the guy I was not the original customer of the battery as it came with the use car when I bought it. This was an outright sale. Now it took 5 minutes to complete.
At home again and put the battery in. So far everything is as it was before the problems started.
--------------
More during this month.
I got sick for 7 days. No fever, still had my taste and smell. Not covid.
It was some sort of intestine problem that cleared up on it's own.
I slept most of the time away.
-------------
My truck which is my backup car was also in this mess.
I was going to town but did even make it to the paved road when a side wall on a rear tire blew.
Change tot he share and went home to get another spare. I have 11 trailers, all with the same wheels so I have lots of spares.

Two days later, anther tire side wall blew on that truck.
Change to the other spare and continued to two, straight to the tire shop.
All the tires that were on the truck are the same age so I replaced all four tires.
-------------
During this time, 2 new speed controllers showed up as well as some new tools. Allen wrench screw driver types. Both US and metric sizes. All orders filled and received.
------------
Now to today.
I was in the shop and installed one of the new speed controllers.
Turned on the Tx and Rx and I got the direction correct first time.
Tested the forward and reverse speed. at 100% on Tx settings.
Both directions seem to have the same speed.
Finally after months of messing with this, I have finally found the right combination of parts.

All the electronics systems work now.
I have one modification I want to do but it is on the aluminum plate that compresses the seals on the rear end cap.
Matter a cutting some of the plate away and using two small bolts to compress the plate.
I have been using the gear box bolts to compress the seals and it has caused binding on the propeller shaft.
Mounting bolts for the plate separate from the gear box will allow me to set the seal pressure and tighten the gear box down without binding.

As of right now, today, everything seems to be back to normal.
I had thought for month the electrical on the car would have to be replaced But it only cost me a new battery which was to be replaces anyway.

And the Gato looks like it may get finished this month.

But for the next couple of days, I plan to get more sleep and rest after such a stressful month. I do mean stressful. Made updated to my Trust.

[Ralph --- SSBN 598]

October 17th ======================

The chaos has gotten back to normal. (sort of)

In the shop this morning I assembled the rear electronics tray and cleaned the cylinder of all the dust from sitting.
Had high winds and dust was every where for 3 days.

Anyway, the rear compartment has it's equipment installed.

I assembled the front electronics tray and hooked up all the wires. (servos and power.
Time to test it all.
Everything works but I had the bow planes retract and pitch reversed.
A quick unplug and replug fixed that.

Time to stuff all that extra wire in to the cylinder.
Several tries and I am close but it is not right yet.
Something is putting pressure on the bottom of the tray at the back making it hard to get the end cap in the cylinder, square.

I am going to have to work on this to see what the problem is.
Maybe I need to remove some of the wire if I can.

Just had a thought.
The issues is having enough wire to pull the rear tray out to get to the plugs.
The wire sticking out the front when the rear tray is in the cylinder.
Maybe I can make a couple of piano wires that hook to the wires that will go through the ballast tank through tube and have just enough wire at the front to hook up the tray.
That could remove about about 8" of 2 servos and 2 power wires.

This is something to check on.

I have 5 days to try to fix this issue.
Next Saturday is a gathering at the lake.
Water trimming only takes a couple of hours to set if my ballast tank extension is right.

I have 4 full days this next week to work on this.

[Ralph --- SSBN 598]

October 18th ======================

Out to the shop.
Does not look good for getting anything done today.
It is very windy and there is so much dust in the air, I do not think working with o-rings and grease is a good idea.
So I covered up everything with a plastic bags and will try tomorrow.