Part of cruising is fixing your boat as you go. If you have the luxury of a new yacht, there are easily attainable replacement parts for all the gear you have onboard because it is all new and probably still in production. If you are cruising on an older yacht, this luxury, along with many others, has probably been lost to time.
On our deck is a very old manual windlass. This machine is very simple and works all the time. The issue is it is very old and parts for it are hard to come by. The windlass needs to be filled with grease and the instructions to add grease are simple:
1. Remove the windlass from deck.
2. Hold upside down and fill 2/3 of the way with grease.
3. Reinstall on deck.
This sounds simple enough, but the problem is there is a very old gasket under the windlass that keeps all of this grease inside the case. I could always manufacture a new gasket out of a rubber material, but why find extra work when there could also be an easier way around it?
I pulled some bolts out of the side of the windlass and pumped grease through the holes into the unit. This worked well to silence the gears, except for one. The top gear on the windlass seemed to escape any grease, making it hum as the gears would turn. In this situation, I decided to create my own tool to inject grease under pressure into the top gear of the windlass!
I would take a bolt that fit the windlass and attach a Zerk grease nipple to it. By threading the bolt into the hole at the top gear, I would be able to push grease in with the power of a grease gun and silence the top gear!
To start, I purchased an identical bolt, simply made out of steel instead of stainless steel, this would make my life easier as I machined it.