Trojan 440 Upgrades, Fixes and Ideas

Wow glad to know that I'm not the only one still fixing up my boat!

Since someone brought up the topic of the front vent, do you guys find that it actually does something? When I open mine, I know some air is flowing because the first time I did it, some built-up dust blew all over the place, LOL. But we certainly can't actually feel any airflow. As a matter-of-fact, that is one of our only "issues" with the boat so far, the wind protection is so good when underway that sometimes we actually get too hot on a warm day. We don't seem to actually notice/feel any airflow when the front vent is opened. We've thought about putting fans up front because there just isn't that much air when underway.

Also, can anyone help with countertop replacement in the cockpit? We have a 1998, so it doesn't have the flip up covers, it has the two open countertops with the very LARGE radius on the fronts. Ours is the yellowish color and we want something more grey/siver/black-ish. I'm not sure what kind of material and fabrication method can recreate that large radius without a bunch of seams or layers showing. Has anyone tackled this before?

Lastly, and I think I've asked this before but I still can't figure it out...how do you turn on the makeup vanity lights in the master bedroom? There are push buttons it looks like BEHIND the bulbs, so do you press on the bulb to engage the switch to light the bulb or ??? We've been using the boat for a year now and still can't figure it out.
 
There are 3 switches. One is the 12v overhead lights, one is the mood lights. The vanity lights are 120 volt and have a unique bulb. I replaced mine with two LED strip lights.
 
Ok finished another project that has went over pretty good. I installed some 1/4 stainless led lights in my bow rails and I really think it makes the boat look elegant.

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Also took my stripe of to put a new one on but I am going to leave it off, to me it looks cleaner and makes the boat look newer.

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The lights look great! Must have been a PITA to install them.
 
quote:
Originally posted by HOGAN

The lights look great! Must have been a PITA to install them.

Click to expand...


PITA sounds like an understatement!
Nightmare to drill Stainless and I can'e imagine wiring them with only a !/4" hole!
But looks cool for sure!
 
Todd,the lights looks great!
one of first thing I did when I got the boat was to remove the strips,agree looks more modern.
 
This past weekend we help for another RO I flushed my steering system and bleed the air from the lines. I'm not sure why but the past two year I have found oil on the floor near the steering and I had very little response from the wheel last year I simply added fluid but I didn't follow the directions and had oil seeping out for weeks but the steering worked fine for the entire season. This year I was told to follow the directions and flush the system, my friend had a nice little setup to make the job a bit easier. When I flushed the old oil out I was surprised at what it looked like, it no longer looked anything like the correct oil it looked more like sludge. I'm thinking it my have water or broken down so much that it was able to freeze pushing a bit of oil out the pressure release value. Now that there is fresh oil and no air the wheel is very smooth.

Has anyone else flushed your system? I'm thinking mine had 20 year old fluid!
 
Dave,
You may want to check to see if your cylinder is leaking as well. if it is leaking it will need to be resealed. I m in the process of ordering a seal set and new hoses from the hard copper to the cylinder. I have a Sea Star model BA200-5 part number HC5951.
 
My cylinder doesn't appear to be leaking. This said the color of the old fluid that I removed would likely indicate that eight seal/gaskets or the rubber hoses seem to be breaking down. On my model I have to pull the dash panel just to access the filler cap I keep saying I'm going to add and extension tube but I never seem to get to it. I need to just order it so I have it on hand the next time I pull the panel. It is a project just to check the oil the way it is now!
 
Dave
I had to add fluid to my steering but didn't flush it. I noticed the steering was not smooth (jerky) and discovered it needed fluid. I added ATF.

Regarding my previous repairs, I was able to get to the leak under the master head shower handle by removing the back couch cushions in the saloon area. That gave me access to it even though I still had to work on my back with my hands extended back from my head.

The vent is also repaired with a new linear actuator and weather stripping around to seal it up. I actually used it over the weekend when I was out to the Channel Islands. There was water spraying over the bow so it was nice to keep the eisenglass closed and still allow air to flow in.

Mike
 
DO NOT use ATF in your steering!!!! You have to use hydraulic fluid.
 
+1 ATF was destroy the seals and cause more leaks and problems!!
Now you need to flush the system and get it all out then bleed the system.

"Recommended oils for your steering system are: SeaStar Fluid, P/N HA5430 (1 quart), HA5440 (1 gallon). The following brands are acceptable: Chevron® Aviation Hydraulic Fluid A, Esso® Univis N15 or J13, Mobil® Aero HFA, Petro Canada Harmony HV115 (in Canada only), Shell® Aero Fluid #41, Texaco® HO15 and other fluids meeting MIL SPEC H-5606-G.

Automatic transmission fluid (Dexron II®) may be used in an emergency. Never use brake fluid. Any non-approved fluid may cause irreparable damage, loss of steering, and cancellation of warranty.

In cases of extreme emergency any nontoxic, nonflammable fluid may provide temporary steering.

Generally, 2 quarts are required for single station, single cylinder filling. Add one quart per additional station or cylinder.

Please note that SeaStar Capilano systems use Dexron II ATF, not SeaStar steering fluid."
 
Hi Dave,

Oops! Well I did put ATF in the steering but it actually said it could be used in one of my manuals. I plan on doing a flush down the road and will add the recommended fluid. What do you recommend to use for flushing?

I took the boat out over the weekend to the Channel Islands. We were blessed with the ocean being flat as a pancake! Wow, what a treat and a great trip. Averaged 25 mph the entire way!
Upon returning I had a problem filling up the Starboard fuel tank. I think it was a problem with the vent line. The vent line cap had broken off at some point before I bought the boat. Maybe some dirt got in there.
After filling up the port tank and returning to the dock, I ran the fuel transfer pump moving fuel to the starboard tank. I could hear the vent gurgling. I let it run until some fuel squirted out hoping it unclogged it. I would like to change the vent fitting with a new one that has a cap like the other side. Does anyone know how to access the inside of the starboard fuel vent fitting and where I can find a replacement? It appears that access is from behind the electronics panel in the saloon.
Thanks,
 
"Please note that SeaStar Capilano systems use Dexron II ATF, not SeaStar steering fluid."

Assuming you don't have a Capilano system then simply flush with and replace with SeaStar Steering Fluid until it comes out the correct color.
 
Hi Dave,
Thank you for your reply. I will take another look at my manuals.

Have you or anyone else replaced the starboard side fuel vent? It appears that access my be very difficult.

Thanks.
 
This board has been dead for a while. Everyone's out boating I guess!

Can anyone tell me what brand windshield wiper assemblies were on the Trojans? I need some parts....
 
AFI 2000 I replaced both mine last year. I had the smaller model the 1000 and made the mistake of install too large of a blade and broke the internal gears. I replaced them with the next model up and I have been very happy.

As for using the boat yes as much as I can we are going away for the weekend on friday.
 
Thanks Dave! At least I'm not just on here talking to myself LOL!

Yes, I had an opportunity to be up at the boat this afternoon and after measuring some stuff, I found out that I have the AFI 1000's. What's weird is there are 24" arms and blades on them, and AFI/Marinco's documentation said the 1000's are made to swing up to a 16" arm and blade, while the 2000 swings up to a 24". So I'm kind of wondering if Trojan/Carver put the 1000's on with 24" arms and blades? Would be kind of silly if they did, but it would also be kind of silly if they put 16" arms/blades on such a gigantic windshield.

Anyways, oh joy, looks like I'll be buying a pair of motors for the inevitable failure. I always thought they were kind of hurky-jerky when they wiped. Now I know why...

On a brighter note, we've put on 100 hours in the last 15 months so at least we're using her a little bit.
 
Can anyone tell me how to access foward head vent fan motor, seams like I'm missing something:( also would like to thank all involved in this thread for great info....
 
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