For the love of a working toilet

Welcome to the story of our first major boat improvement project -- replacing the holding tank for the head (toilet).  We had an inkling when we bought the boat last year that trouble lay ahead with this tank b/c it was constructed from alumininum, which is about the worst choice possible due to the caustic nature of urine (what were those brilliant boat designers thinking anyway?).

The boatyard quoted a price of $6K+, which motivated Dan to go online with his Bayfield Yacht user group to see how other people have handled this issue.  Sure enough, Dan soon became fast friends with Bill who provided him with detailed pictures and directions for how he had tackled a similar project. Coupled with his box of Dewalt tools, Dan set about cutting out the old alum tank and preparing the internal space for a new, custom-built plastic tank (good for another 20 years!). 

Ordering a new tank required precise measurements (which required building a model from cardboard and simulating where all the hoses and connections would fit).  Once the order was placed, we settled into waiting for it to arrive, resorting to a rustic system of putting a bowl in the toilet, transferring the contents to a plastic jug, and carrying the jug up to the boathouse bathroom under the cover of darkness.  The one thing we did not count on was the wind that would whistle down into the cabin from this opening. Brrrrrr!

When the tank arrived, we rejoiced that it fit!  Even though the company made two mistakes with Dan's specifications, Dan thought he could work around those issues.  Ever the optimist.

Next began the many trips to various stores for supplies.  First stop, Home Depot for the wood that would be used to secure the tank in place.  As I'm sure you can appreciate, a full holding tank is the LAST thing you want moving around as the boat heels from side to side!

Stops #2 - 25 were to West Marine for all the speciality hoses and valves and hose fittings required to complete the assesmbly.  Hoses run everywhere -- from the toilet to the holding tank, from the holding tank to the over-board discharge (something that is legal to do 3-miles offshore), hoses that bring sea water into the toilet, etc, etc. etc.  Many decisions had to be made about which expensive part to get -- and this is something we learned that everyone has an opinion about!  So you end up spending most of your time collecting opinions, doing research on the internet, comparing review and prices, and then making the final decision.  Of course, once that decision was made, we invaribly discovered that the part or hose was not in stock at West Marine.  So the routine of waiting for the weekly parts delivery at West Marine began.  Dan would get as much as he could get done before needing to wait for his order to arrive on Saturday.  We spent every Saturday over at West Marine!

As expected, Dan did a masterful job of laying out the hose system to minimize the length of hose required for the installation and to reduce the degree of bends in the hoses as they snaked from the hull fittings to the various openings on the tank.  All good things b/c the less distance the waste has to travel the better, and having fewer bends in the hose where "stuff" can get stuck .... well, that just makes sense!  Considering that this speciality hose runs $10/foot, precise measurements matter and Dan tried several different configurations before getting it just perfect.  And perfect it was!  Actually a work of art when it all came together (I know this may be hard for some of you to appreciate, but that's because you have the luxury of taking a working toilet for granted!  Something I've come to envy!)

We bought a new macerator pump (it does just what you think it does!).

Nice, huh? All shiny and new....

It was no small feat for Dan to come up with secure place to install this new pump in a spot that could be bolted down and yet not interfere with the web of hoses.  The space he is working in is now very tight with the hoses and connectors and wooden frame.  Each simulation of how the whole thing would come together actually required assemblying the whole thing -- checking measurements and placements and bends -- and then disassemblying the whole thing to get into a tight space to secure a pump or hose or connection in place.

See.... I wasn't lying ... a work of art when it all came together!

Sunday, March 7th

Dan is ready to make the final connections and declare this project done!

The champagne is on ice.

I'm ready with camera in hand.

 Uh...Oh...

What's with the look on Dan's face?

Where did that smile go?

Why is he swearing so much?  And not under his breath anymore?

See that black connection on top?

Well, it's supposed to be 4 inches to the right so it will clear the anchor drain connector (the white piece at the top of the compartment -- hard to see).  An elbow connection needs to go there to connect the anchor drain to the main tank assembly. And without those 4 inches, the 1 1/2" elbows do not clear each other and the final hose connection cannot be made.

The company that fabricated the tank made this mistake, and it's not one that Dan can jury-rig an alternative.  There is simply no space.  That top connection must be moved 4 inches to the right. So, the champagne stayed in the refrigeration, and we had a rather glum dinner that night as there were big small success to cheer about.  Instead we discussed all the things we'd like to say to the company that screwed up Dan's precise specifications.  After much unpublishable venting, we sent an email to the company explaining their error and their responsibilty to replace the tank.  Even though the invoice clearly stated that all sales were final and they were not responsble for much in this world, we went to bed with our fingers crossed. 

We are now big fans of companies based in Maine! They do take pride in their workmanship, and customer service is indeed alive and well.  They were truly apologetic for the error and said a new tank would be in the mail the next day.  And it was.  It will arrive tomorrow.  Then, with fingers crossed, Dan will take everything apart (for the hundredth time) and reassemble it (hopefully for the final time).  And, then we'll crack that bottle of super cold champagne!

Finally, March 15:

The new holding tank arrived!  (Actually, it arrived in Brunswick on March 12, but as our luck with this tank goes, the company used the wrong address, so Dan had to go pick it up at the UPS office!).  

With all the practice he's had, it didn't take Dan long to disconnect and remove the other tank (no small feat, considering all the hoses and valves and clamps to deal with!).  Out with the old and in with the new.  So many hoses to account for -- one goes to the holding tank, one goes to the macerator pump, one goes to the overboard discharge, and one goes to the anchor locker (I know it may seem that the anchor locker has nothing to do with the holding tank, but the anchor locker is located in the front/bow of the boat and when we go crashing thru waves at sea, all that water has to go somewhere ... and we'd prefer it not come pouring into the boat!). The two valve handles direct the flow of waste -- to the holding tank or to overboard when we are offshore. 

After several hours spent wrestling everything into the proper place, it's finally Miller Time for the My Hero! (actually St. Pauli Girl Time)!  Dan is one happy man ... deserveably so!

Tah Dah!  Almost a shame to use it because it will never look this good again!

Dan still needs to remount the toilet paper holder and put up the shower curtain rod (shower is on left) ... but we are officially open for guests!