Cape Dory 27 Voyager Edition Refit Tour

The modifications to this Cape Dory 27 "Ma Ha" Voyager Edition sailboat were completed in 2023 by Cruising Yachts Services in Brunswick, GA. Voyager Edition is used for boats we have gone through thoroughly top to bottom making repairs and modifications to make them more suitable for offshore voyages, including new sails from Rolly Tasker National Sails, new rigging, self-steering, integral water tanks, collision bulkheads, plumbing, electrics, ground tackle, and many more. Check the Cape Dory 27 playlist for more details of the projects shown here.

Our sea trials on the ePropulsion Navy EVO 3.0 electric outboard motor and Tohatsu 6 hp Sailpro gas motor showed the Tohatsu pushed the boat at 5.6 knots. We gained about a 1/2 knot from when it had an inboard diesel engine by not dragging the inboard prop and by eliminating turbulence by filling the prop aperture in keel and rudder. The increased rudder area by filling the aperture enhances the steering.

The electric motor gave us 5.15 knots top speed which is not quite as good as the 6 hp Tohatsu but still acceptable since our goal was at least 5 knots. The graph in the video shows the speed/watts/range results which show that the range with one 80AH battery is between 6 to 21 nautical miles depending on throttle setting. The regeneration under sail was disappointing. In our first test we got 45 watts battery charging at 4.5 knots sailing speed but more typically we got less than 40 watts at 5 knots boat speed.

Despite the success of our modifications this is not intended to be an endorsement for replacing your inboard diesel with an outboard motor. We have significantly less power available to push into wind and waves. The top speeds we achieved above 5 knots will fall off quickly when going against headwinds and waves. It is intended as a low power alternative propulsion system for keen sailors rather than the more common motorsailing yachtsman who only raises sail when convenient.

It takes about one hour in calm waters to swap out the electric and gas motors so it's not something you want to do frequently. But the option is there when needed. We envision using the electric for most situations but swapping to the gas motor for long trips in waterways or in the Panama Canal. Dual propulsion systems also serve as a backup in case of a breakdown.

Another downside is the quality of the Epropulsion components we recieved and some issues with the design features. Within a few hours of testing the E80 48 volt lithium battery became faulty as well as the remote throttle diplay. Both were replaced under warranty after lengthy delays. Quality control should be better.

Components from Epropulsion dealer Annapolis Hybrid Marine:
Motor: Evo 3.0 $2,999 long shaft (53.6 lbs, 62.5A, 10.2″ × 6.7″ 2-blade composite propeller, static thrust 132 lbs)
Or for more power you can instead order the Navy 6.0 with E175 battery.

Battery: E80 4kw (80AH) LiFePO4 (Lithium Iron Phosphate) $2,299. The manual states you must use this ePropulsion battery in order to enable the regeneration charging under sail feature.

120v AC to 48V DC battery charger: Epropulsion AC battery charger (20A)

Evo Side Mount Throttle Control: $499

DC-DC converter for charging the 12v house bank from the 48v motor battery: 9 amp Victron Energy Orion-Tr 48/12-9A DC-DC Isolated Converter $67 online or from Annapolis Hybrid Marine.
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Epropulsion Y-type communication cable to connect motor, side mount controller and battery.

Epropulsion battery remote switch.

If using two batteries in parallel, order e-battery y-type communication cable and a second 1.5 or 2m comm cable between batteries.
A "communication terminator" is not needed if using a remote switch because it is built in to the switch cable.

Extra battery cables and fuses for your particular installation.

Solar battery charging options:

48v Solar controllers:
Boost MPPT Genasun GVB-8-48-Li-FF:
https://cdn.shopify.com/s/files/1/006...
$190 https://www.amazon.com/Genasun-GVB-8-...

Or use this less expensive 12 - 48V 300w boost MPPT for $50. On a Cape Dory 36 we used two for a 400W panel array:
https://www.amazon.com/SUNYIMA-Contro...

12v solar controller:
Victron Energy SmartSolar MPPT 100V 20 amp 12-24-48 Volt Solar Charge Controller (Bluetooth) $150
https://www.amazon.com/Victron-SmartS...

Two transfer switches for solar charging 12v and 48v banks: Szliyands Universal Rotary Changeover Switch LW26-32, 32A, 3 Position, 8 Terminal $16 each. These switches are only rated for AC current so if using larger solar panels you might need a DC rated transfer switch.
https://www.amazon.com/gp/product/B08...

Music: The Rain Song (cover by Chiara Kilching)