Fabrication

Headliner

16 May - The Sail Loft Canvas girl came by today to assess the headliner and cockpit cushions

• She has several ideas on the headliner, she is going to work up estimates etc for us to consider

• The cockpit cushions are also being completely redesigned to make them more functional and more comfortable. Again she is going to work up some alternative approaches with materials for us to consider

2 Jun - headliner from forward berths removed. Found additional rot around the prisms.

4 Jun - Met with the sail loft. We are discussing the best way to create and then reinstall the new headliner, nothing definitive yet.

9 Jun - All headliner is now removed and measured to be rehabbed

10 Jun - rebuild plan is taking shape - cut plan for new plywood is settled and vinyl and foam is at the sail loft. Ready to order replacement plywood.

2 Jul - The replacement plywood for backing the headliner is mostly cut.

Dec 2025 update -

We are nearing the point where we can start re-installing the headliner. The deck hardware is being reinstalled along with the Solar Arch and Cockpit Hardtop. Additionally, the electrical and electronics work is wrapping up. All of those tasks need to be complete prior to reinstallation.

We also decided to redo the "headliner" in the heads. This was actually plywood faced with Formica. All of those panels are now remade and are ready for installation.

Sail Locker & Termites

The termites were unknown to all parties at the time of the sale. The fumigation and tenting cost $4K but did an effective job of killing all the bugs (termites, roaches, etc) inside the boat. As we got into digging through the guts of the boat, we were able to determine the extent of the termite damage. The biggest issues where in the sail/ chain locker where they had consumed most of the wood present. The whole area will need to be rebuilt. So far we have cut out the primary floor and support as well as the partial bulkhead between the sail locker and the chain locker.

The drawings on the left are the sole of the sail locker and the bulkhead shape.

Rebuilding

1. Convert bulkhead between forward berths and locker area to be water tight - (Remove hatches, remove drains at base, seal up) - discovered more rot at the base of the bulkhead - this appears to be an area that was added by a previous owner and the damage had not migrated into the primary bulkhead structure.

2. Setup a remote bilge pump to pump out this space and a high water alarm sensor

3. Replace the washdown plumbing so we can just plug a hose in.

Dec 2025 update

The work continues a bit at a time. The crash bulkhead is patched and coated with fiberglass. It is awaiting punching a new bulkhead fitting for the raw water washdown supply hose.

The sail locker floor is also installed. Unfortunately, the yard labor was pulled off to work on 2 other boats, so rather then being able to wrap up the bow, we are back to waiting for this project to wrap up. The chainpipe also needs to be fabricated and then we can decide how much chain we can go with.

The new anchor is ready, the windlass is sitting in pieces awaiting reassembly and the plumbing parts and pieces are also on hand. Once the fiberglass is done, everything can be painted and then we can start re-installing everything.

AFT Berth

The picture to the right shows the port cockpit deck drain hose and connection. It's been leaking for quite some time and the plywood right underneath the cockpit fiberglass is badly rotted (water damage) around the drain.

The air vent for the main engine exhaust is also damaged and has been leaking and will need to be replaced.

The hot water heater is going to be relocated into this berth along with the fresh water pump (under the AFT berth). The solar panel MPPT Controllers (Starboard storage area) are also going to be located near the hot water heater (Starboard storage area).

The autopilot computer and ram controller, and the Hull Shield controller for the 2 units for the rudder and running gear are going to be located under the AFT Berth along with the Air Conditioner.

Dec 2025 update

We have now mounted everything under the berth other then the air conditioner. Everything still needs to be connected and tested.

The engine installation will also address all of the berth front cabinet dependent systems (starter batteries and associated wiring, deck drains and the exhaust for the main engine)

We are also replacing the steering conduit and cable that runs from the engine room to the lazarette through the berth's sole area.

Lazarette

The termites came all the way back here, but the primary issue is water damage. All of the wood in the Lazarette will need to be replaced.

Propane locker needs to be cut out as we are not going to use propane and the space is better used within the larger lazarette

14 Jun - Cut the remaining parts of the propane locker out. Did an evaluation of what appears to be an after market addition - the aft bulkhead. It appears the transom stair access was made by a previous owner. This access was just cut out of the existing fiberglass stairs and no attempt was made to make it water tight. So they fabricated a bulkhead between the far aft storage and the main lazarette. This bulkhead was not professionally installed, in fact the fiberglass work as poor at best - never sanded smooth and the surface prep prior to glassing was not done and now much of the glasswork securing it to the hull is delaminating. We considered removing the bulkhead as it is in the way of other things we want to do, but because the aft stair access will allow water in, we can't without fixing that issue. Something for us to put into a future yard period.

Dec 2025 Update

Well the back stairs have long since been glassed back to factory configuration.

After waiting for several months for the Yard to finish cleaning up after themselves, I was able to take the first "cold" day we had in Oct and climb into the Lazzarette and grind for almost 2 days to remove the remains of the cut out bulkheads and crappy fiberglass work that had been done by a previous owner. The yard guy did finally cut in the new air inlet hole, but never finished that job.

While grinding out all of the remains, I discovered we had more water damage in the bulkhead between the berth and the Lazzarrette. That work has been added to the yard's fiberglass work list. For now everything in the Lazzarrette is on hold awaiting the completion of the fiberglass work.

The work on hold:

1. replace the steering conduit / cable

2. Service the rudder bearing and bushing (hopefully we can clean and grease and not have to replace)

3. Reassemble the quadrant once the rudder is reinstalled

4. Install the Hull Shield Transducer for the rudder

5. Install Lazzarette lights

6. Install the shore power hookup

7. Install the dinghy motor charging port

8. Install the compressor outlet

Salon

The Salon area is primarily water damage from leaking overhead hatches and dripping onto the cushions which held the water against the wood they were resting on.

There may be more wood removed, but so far we have removed the floors of 2 of the 3 storage sections (the 1st 2 will be the home for the new batteries) and the bench seat. The lower area of the back rest also has peeling veneer, but we have not decided our approach there yet.

9 Jun - got all of the cut pieces primed.

The drawings on the right are the salon cushion bench and floors of the storage below.

Dec 2025

The salon seat bench is in place and protecting the batteries. The batteries need a firmware update (at a minimum) so we need to get to them again. When that finally happens, we will "permanently" install the bench seat. We also likely need to run some more wire to support the mast wiring. So we are not in a hurry to wrap up the seat project.

We discovered that the captain's chairs were actually repurposed office chairs that were not converted using "expert" techniques. We have a plan to upgrade them, and one is now done, we will do the next one once the GenSet is reinstalled in Jan.

Forward Berths & Heads

Both soles in the forward berths need to be replaced due to termite damage.

The port head was only partially decommissioned and the associated thru hulls were not removed. We will close them as part of this rehab and clean up the abandoned plumbing in the area.

Also there were 4 transducers located in the hull in this area. We will only use one of these thru hulls for the new DST.

5 Jun -

Turns out the termite area was a repair after the boat was made. There is a clear cut line separating the damaged area from the undamaged area. It is not clear how the sole is attached to the frame/ hull of the boat. Reassessing how to do this repair.

Dec 2025

Ok lots of progress to report in this part of the boat.

Port Head/ Tool Room

Once we really got into the wiring and plumbing, we decided that it made more sense to rip everything out and start again from scratch. We have now installed new more functional shelves in the tool room and have fixed the plumbing woes that ran through there. The old thru hulls have all been plugged. We also addressed some of the wiring issues in this area.

Port Berth/ Storeroom

We have decided that this space is going to be strictly used for storage and systems. The thru hulls in this space are now plugged and the new raw water intake is awaiting the hull remediation to wrap up to be installed. The bilge area is also freshly painted. This thru hull will feed the water maker, Starboard Head flush water and finally the anchor wash. The hoses to support all of these systems is now in place and the water maker part is all hooked up. The Anchor was is plumbed through the pump and awaiting the forward bulkhead work to wrap up to be punched through a new bulkhead fitting. The head is awaiting final toilet install. We also decided to convert the handing locker in this space to be our new pantry space. The shelves and supports are all ready for install, but until the wiring in this area is finalized and above the water line thru hull for the water maker discharge is installed, final installation is on hold. We also removed the natural light prism for refurbishment. It is also ready for reinstall, but the surrounding fiberglass may need some TLC - TBD.

Starboard Berth

The Thru Hulls here are now plugged. The bilge area is painted and now we are ready to install the new thru hull for black water discharge as well as the DST 810 Transducer and the hull shield transducer in this area. There is also a prism on this side that is pending fiberglass remediation.

Starboard Head

We decided that we would remove the shower capability in this space. All of the plumbing lines are now replaced. The toilet install is awaiting a new starboard base. We can then put this back together. The Sink also needs to be modified to accommodate the test facet for the water maker.