After going all summer using the Hercules* method of raising the anchor, I've finally gotten around to opening the windlass up and seeing what the problem is. (*Grab chain and raise by hand. Get a great workout. Get all covered in muck. Pull. Pull. P u u u u l l l.)
See Sailnet Post - w1ndlass just goes click
First, I took the windlass off the boat. After rebuilding both the "mystery blower" and our washdown pump in the last few weeks at home, I saw how great it is to actually spend time with your family while working on a project, instead of disappearing all day to a cold, far away, cluttered-with-projects boat to make progress. With a lot of snow on the ground today, and time indoors to spend on a project, this approach really paid off.
Here's a picture of the windlass on the bow, taken while working on removing it. (I had the motor cover off in this picture).
One of the bolts was pretty tough - the washer and nut were partially tabbed in place, so I had to chisel through some fiberglass to get a wrench around it. Here's a shot of the tabbed-in-place bolt.
The I used a dockline tied to the jib halyard to lower the very heavy windlass to the ground. The spinnaker halyard would have been better, but it rained halyard in the fall while I was putting winter lines up. (There's another trip up the mast in my future.)
Back at home, I commandeered the dinner table for a day. With a little bit of liquid wrench, I managed to get a few parts off. Here's a video of my getting the first few parts off. I was learning as I went, as you'll soon see. (I used Liquid Wrench, not PB Blaster as I said in the video. Inside the house, I didn't want everyone breathing the fumes all day.)
Click here for video (10 Megabytes)
I could not get the gipsy (the thingy where the chain links fit in) off it's shaft. And one of the allen-wrench type bolts was really stuck. So a quick call to our car mechanic was in order. Plowing through all the snow in the driveway, I got to his shop, handed him some money and a great Unibrau beer with the words "I know you time is valuable so I'm giving you this for just looking at this thing". (Very true and I really like having a happy mechanic that I can call.)
Bill Anzelone got the gipsy off the shaft with a "pop" that made me jump. I didn't expect a loud noise and such a sudden motion when it snapped off. Then he went to work on the partially stripped bolt. He applied heat, tried a few things, and in the end got the bolt out by hammering the next size allen wrench (hex shaped) driver into the bolt and then using an impact wrench. I NEVER would have gotten that bolt out without Billy's help.
Here's a shot of Billy.
He also took the electirc motor off the windlass. There, laying between the ridges on the worm gear was a small piece of metal. Yeah! That was the cause of the windlass just going "click". I still have no idea where it came from. It doesn't match anything on the parts diagram, that's for sure. (Maybe BullyRuffin' put it in there, thinking that it was me who put those bolts in his engine bilge. A.k.a., how to drive a meticulous sailboat owner nuts.)
Mystery piece of metal that was lodged in the worm gear.
Billy Anzelone and I couldn't get the next disk-thingy off and we didn't want to break anything when the parts breakout should be consulted first. So he loaned me the cooking pan and helped pack everything back in the car. My homework was to 1) drain the oil, 2) check for other loose parts sitting in the oil, 3) check the parts breakout, 4) see if I could slide the shaft out without taking the disk-thingy off the shaft.
Windlass sitting in our car, now partially taken apart. The body of the windlass is filled with oil, so it had to stay upright. Everything else was wedged in next to it, to make sure it didn't tip over.
I ended up doing my homework exactly as he said. Here's a shot of the windlass back on our dinner table. The allen wrench bolts are all out and the shaft is ready to slide out. SO I THOUGHT! I had to remove the key on the right first. (The thingy shaped like a mini loaf of bread that is embedded into the shaft.) I was wondering why the shaft wouldn't slide out all the way. Then Grandma - of all people - pointed it out. I guess it pays to marry an engineer as she did many years ago.
Removing the key. In the end, I put the vice grips in the middle of it and wiggled it out.
Disassembled at last!!!
Now the second discovery. There's a spring that holds the latching thingy against the bumpy thingy, so the windlass doesn't go into free-fall on it's own. The spring was broken and one of the bolts that holds it in place was bent.
Also the other piece of the broken spring was lying in the oil inside the windlass. Billy Anzelone cautioned me to look in the oil for other pieces. He's good!
Note the bent screw
For those of you wondering what the inside of your windlass looks like, here's a picture. Half way down the hole you'll see a rubber "O' ring. I have the "seals kit" for this windlass and plan to replace the seals. Of course, that means I'll have to get that stubborn disk thingy off the shaft because there's a seal behind it.
This thingy needed cleaning. I scraped with an old screw driver to get rid of some of the oxidation. If anyone knows a good cleaner to use, let me know. I think this piece is not aluminum. Bronze maybe?
Here's a before and after where I cleaned one of the springs. I'll need to re-lube these, so I'm planning to ask Lofrans what type of grease to use. (I have grease that came with Defender's outboard winterization kit. Maybe I could use that.)
Now I better order the new parts from Lofrans and clean up the dinner table before hitting the sack tonight. Next time I'm going to completely cover the table with newspaper before starting. I think I played it a bit risky this time.
I intend to post an update after the parts arrive. Meanwhile, I'm wondering if I should use some On&Off to the outside of the windlass to restore it to it's previous beauty.
All in all, a lot of progress today!
P.S. Here's some windlass eye candy. Its a picture of our boat when it was new and a member of the Moorings fleet. Note how shiny the windlass was a decade ago.