Sampson Boat Co
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...grinding sound, continued
🕑 Added 2026-01-14 20:32:40 +0000 UTC...after hearing a worrying grinding sound coming from the engine room, I investigated and found that one of the electric motors in our hybrid system has failed - the pulley-wheel won't turn freely, has play, and is spraying small metal filings! Probably a bearing failure, leading to collisions between the rotor and the stator.
At this point we had half of our sails up, so we continued to hoist everything and then after a short journey we anchored under sail to investigate further.
At anchor, it was easy to remove the drive-belt from the hybrid system - at least now, I could use the engine for propulsion, but without the belt in place, we are unable to charge our 48v battery bank. This isn't the end of the world - the most critical systems are on 12v and can be charged using the engine alternator, but it does mean we can't use our cooker, or any other AC appliances or tools.
I talked to Hybrid Marine who were incredibly helpful, and offered to send out a new motor free of charge (they were surprised - we must have got a bad motor somehow). This is great news, but shipping a motor will take some time, and in the meantime we need to keep making progress towards Panama.
The solution? Find a shorter belt so we can run / charge the system using only one motor, until we are able to replace the faulty one. The challenge? Finding a very specific industrial belt in Costa Rica over a public holiday!
(spoiler alert - we eventually found a belt, and got a new crew member in the deal too)
Comments
Lee Gibson
I wager the loads in the belt to run the motor/generator are WAY higher than a fan. But it’d be worth a shot!
Warren Mangan
I assume Hybrid marine were able to give you the code number for the shorter toothed belt ! Made that tricky search a little easier! Cheers Warren
Allen Matteson
If you all had been watching and paying attention, Tally Ho explained previously that the complex engineering onboard is necessary to make and post this content you all enjoy. Without your support of this project it very likely wouldn’t be possible. So perhaps your criticism of complex systems is misguided.
Dan
Sail on!
Lance Daniels
Glad to hear that the company offered the replacement, and that you were able to get the drive belt that was needed. Thanks for posting and sharing.
Terje
Hi Leo! Hope you went to visit Corcovado National Park while in Puerto Jimenez. We were there last week, and it was amazing!
Adrian Nicol
hmmm... two alternators but one belt, a likely single point of failure if ever I saw one ...not the best design from a redudancy point of view! Any chance of re-jigging the layout with a double drive pulley and two belts?
SheriffJohn
I wanted to add that I helped my friend who bought a slightly used 55 ft ketch and sailed it from Tampa Florida to Louisiana, mid way, a fan belt broke. We had no spares. We managed to tie a few bungee cords together to make a fan belt. It worked, although we kept our fingers crossed for the rest of the trip! Good story now not so much at the time. Think up side down, boat wallowing trying to make it work. Fun really
SheriffJohn
Since you are getting close to Panama, gotta tell you that I went through the canal years back and it was amazing! What I remember most was the smell in the air. The air was something else, hard to describe but the air was hot and strangely sweet and thick. You could smell the jungle green and sweet aroma of jungle flowers. I hope that your crossing will be as exiting for you as it was for me.
Gary B
Great to hear from you, Leo! We're all rooting for you. I am sure, with your "can do attitude," asserted by some many others in your videos, that you'll find a solution, and proper. Can't wait to watch the video on your Panama Canal trip! Good luck!
Paul Haynes
I was very pleased when you opted for a hybrid system, but it seems to have been cursed!
