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Thread: Spring work down at the boatyard and workshop

  1. #1
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    Cool Spring work down at the boatyard and workshop

    Spring just round the corner new projects are coming in to the boatyard and the workshop, this project is going to have a complete refit with a lot of wood trims and new bulkheads ahead of its new voyages as a expedition yacht in high altitudes in and around Norway, Greenland and Iceland and further afield later on.


    The decks are a complete mess and the first job for the Team is to clear the mast off the yacht and put it in the roof space of the workshop and then give the deck a god pressure washing to clean the decks up so the we can see where to start.


    The owner as asked for all the deck fittings to be removed and the decks made good



    All the old deck hardware to be renewed with up to date equipment and to be easily maintained when away from anywhere.



    All the deck covering such as Treadmaster is to be removed and new covering to be put down in its place



    One of the other jobs to get on with is the cockpit drains as these appear to be blocked and needs sort ASAP



  2. #2
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    Default Re: Spring work down at the boatyard and workshop

    The deck fittings on the upper deck are in need of removal as these are past their best as well and in some cases missing of broken





    one of the major tasks is to remove the chain plates on this yacht which is a big job as these are glassed into the hull below the decks







    A new mast step will have to be fashioned and made to fit the new sail management system the owner wish to employ on his yacht







    The spray hood rails and the sliding hatch are all going to have new wood trims and a new set of washboards made.







  3. #3
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    Default Re: Spring work down at the boatyard and workshop

    The inside is going to be completed emptied of it woodwork and new design to fit in with the owners plans for the yacht be after its refit



    A mess now, however after a good clean up and emptying of all the old woodwork in will be a far better place to work and sail in on the long voyages this yacht is going to go on when the work is completed




  4. #4
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    Default Re: Spring work down at the boatyard and workshop

    A new week and the refit begins on the project yacht

    The mast is now undressed and ready to be put in the roof space of the workshop for the duration of the refit.



    The old standing and running rigging ready to be put into storage until it is time for it to go to the rigging shop to be renewed







    The rudder loose fibreglass which is going to be removed and re-glass after it is tested to make sure it is dry enough to glass









    The heel area which is in need of rebuilding so there is no ingress of water through this area







    The area appears to be intact and will just need sanding back before the whole rudder blade is epoxied as part of the underwater area treatment.





  5. #5
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    Default Re: Spring work down at the boatyard and workshop

    The decks are now clear of the Treadmaster non-slip and now starts the big clean up of the deck and any repairs to the sub deck before laying a new Treadmaster deck at the end of the refit





    Some areas are smaller than others and a lot of patience needed to get the Treadmaster off the sub deck in tight areas














  6. #6
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    Default Re: Spring work down at the boatyard and workshop

    The chain plates are now just have to have their selves removed so that they can get removed and new chain plates can be made and new chain plates can glassed in place



    All this old interior is coming out to make room for a new interior to go in that is going to be purpose made to fit the inside and make it fit for purpose as expedition boat











    The old engine being removed to make room for a larger engine to go in its place to give the boat power for punching through the big seas it may encounter on its new voyages





  7. #7
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    Default Re: Spring work down at the boatyard and workshop

    Starting her progress into the workshop



    The plastic bin was a guide to the height between the top of the cabin and the door frame height







    Halfway in and going to plan







    A photo to show how close the cabin top was to the door frame







    The yacht in position for its refit







    My two apprentices who without who's help the job would have not been able to be done





  8. #8
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    Default Re: Spring work down at the boatyard and workshop

    Starting her progress into the workshop






    The plastic bin was a guide to the height between the top of the cabin and the door frame height








    Halfway in and going to plan








    A photo to show how close the cabin top was to the door frame








    The yacht in position for its refit








    My two apprentices who without who's help the job would have not been able to be done





  9. #9
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    Default Re: Spring work down at the boatyard and workshop

    that looks like a lot of work. will be watching.

    jim

  10. #10
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    Default Re: Spring work down at the boatyard and workshop

    As part of the refit of the Morgan Giles, the stern gear as to be looked over, this is what happened when will released the coupling off the gearbox and pulled the shaft aft to inspect the propeller shaft the insert of the cutlass bearing was seized on to thew shaft.



    Another job we were called to, to do this week was to fit out a galley area on a large motor cruiser with a new hob, oven and dishwasher.









  11. #11
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    Default Re: Spring work down at the boatyard and workshop

    It must be spring, Simon, the clients are starting to emerge from hibernation !
    Nick

  12. #12
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    Default Re: Spring work down at the boatyard and workshop

    The coamings are in a very poor condition and are rotten where the fresh water as been able to sit on the cockpit seats.





    The bottom of the Samson posts just crumbed away when they were released from the coamings







    When it comes to re-fitting these coamings the new coamings are going to be epoxied on the areas where water is going to have any chance to lay, we do not want to have the same problem to have any chance to do the same thing twice.







  13. #13
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    Default Re: Spring work down at the boatyard and workshop

    The hull to deck joint was in poor condition as in places it came apart when the toe rail bolts were released, although the two halves are bolted together with their own bolts as well as the bolts going through the toe rails.



    Before ant work can be done on the toe rail refitting the deck to hull joint will have to be re-fixed and sealed to ensure that area is sealed and the strength is re-instated.







    The toe rails off the boat and are now being cleaned before they are repaired and put into storage before being refitted towards the end of the refit.







  14. #14
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    Default Re: Spring work down at the boatyard and workshop

    Lotta work ber.

    I like the fact you have some young apprentices, good on yer.

    Keep it coming....!

  15. #15
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    Default Re: Spring work down at the boatyard and workshop

    All the deck fittings now removed


    All the wood trims removed

    Outside as well as inside the hatchway




    Just one fitting on the deck to remove from ahead of the mast support





    The cockpit coamings are all removed and the area needs a good clean up




  16. #16
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    Default Re: Spring work down at the boatyard and workshop

    It has been a busy week down at the yard with lots of work being done on the Morgan Giles, the Hardy 25 and a Hatteras 53. All the jobs undertaken were using all the different skills the Team at J-Star Marine Services have to offer. This week we took on another part time worker to help with the increased workload we have got to do over the next few months and beyond. The many push now is to get the Hardy 25 finished off for May Bank holiday weekend and down to Bristol to its new owner. At the same time get Mai-Star II deck and other jobs done so that she can go back in the water this coming sailing season.

    At the same time other small jobs are coming through and we are working to get them done, so that the team can have a few weekends sailing Mai Star II in a few local sailing Regattas and win the odd race.

  17. #17
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    Default Re: Spring work down at the boatyard and workshop

    The main bulkheads now removed



    The remains of the bulkheads to come out and so we can start with a clear run at putting the yacht back together the way the owner wishes his yacht to be for his uses







    The engine exhaust fitting being a problem with getting its bolts out







    The bottom of where the Samson posts were fitted which shows they had pegs on the bottom to keep them in position







  18. #18
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    Default Re: Spring work down at the boatyard and workshop

    The battery locker now just needs trimming the edges



    The edges trimmed and hinges fitted







    Finally the vents to keep the Battery charger cool





  19. #19
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    Default Re: Spring work down at the boatyard and workshop

    The old heater locker which has to be reconstructed to look like the rest of the panelling in the area



    The original cover for the heater which was made up of the wrong type of faced plywood





    The original locker sitting on the new covering panelling for the fuel tank which is teak faced like the rest of the cockpit bulkheads



    Now it is time to make a new locker that like the part





  20. #20
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    Default Re: Spring work down at the boatyard and workshop

    Making the new diesel heater box so that it looks more like the rest of the fitted lockers in the cockpit



    The battery locker all finished off now ready to be varnished when the rest of the cockpit get re-varnished towards the end of its long refit







    The old heater front which is being used as a pattern for the new panel.







    The next major job in the cockpit refitting the head lining panels with new vinyl covering to match the side linings







    Then it will be the turn of the carpet linings for the lower level coverings, which will be the colour of the later Hardy 25's which was dark blue and not the brown linings this boat was original covered in which the present owner wishes to be changed to the Blue that later Hardy 25's were covered in as standard.





  21. #21
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    Default

    Seriously, everyone so seriously serious.. 🤣
    Spring is waiting to spring now that we sprung forward, and as my automotive friends say spring is around the corner...

    Sent from my LG-M430 using Tapatalk
    Last edited by DeniseO30; 03-14-2019 at 01:36 PM.
    Denise, Bristol PA, Oday30, Anchor Yacht Club, On tidal Delaware River. my current project; http://forum.woodenboat.com/showthre...0-Ducker-Resto

  22. #22
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    Default Re: Spring work down at the boatyard and workshop

    The panelling from the Hardy 25 cockpit which make aft end lockers and cover up the steering ram and pipe work



    The old locker fronts which are nor fitting well and which are not made out of Teak faced plywood which the owner wishes to have there when the cockpit is rebuild







    The cabin diesel heater locker now going back together







    The fuel tank from the Morgan Giles which had old contaminated diesel and diesel bug, which is now getting a good clean out and de-greasing of any foreign material







    The lid was cleaned at the same time and will be getting a new rudder gasket before it is re-stalled in the yacht later on in the refit.





  23. #23
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    Default Re: Spring work down at the boatyard and workshop

    Fitting the new engine feet to this Yanmar 1GM10 the old feet had completely broken down







    The new fett had to have new bolts fixing them down as the old studs were too short and new bolts had to be sourced to replace them









    Finally got them all done and the engine lined up with the propeller shaft coupling and now ogt to re fit a new cutlass bearing





  24. #24
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    Default Re: Spring work down at the boatyard and workshop

    The bottom now masked off and ready to get sanding the old bottom finish which appears to be an early form of Epoxy protection system which as broken down with age.

    This is going to be a long job for two of the apprentices to do over the next week or so.



    A test patch which as been done to see the extent of the job ahead and to gauge how much sanding it is going to take to get back to the original gelcoat.

  25. #25
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    Default Re: Spring work down at the boatyard and workshop

    The starboard side is now all sanded back to the original gelcoat



    So there are a few areas that need more sanding,however,the worse part of the job on the starboard side is now done







    Now it is the turn off the port side to get the same treatment and then it will need a short time to dry out the areas which are in need of drying off and a few repairs to the back of the keel







    Another project speed boat as come to the yard to have some bottom repairs around the transom area and a new lower transom repair before being painted and have its 2.0 litre BMW engine refitted and put back in commission







  26. #26
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    Default Re: Spring work down at the boatyard and workshop

    Work is now underway on the Hardy 25 with the cockpit refit well underway and the rest of the boat getting underway next week



    Now that other projects are now finished the Mai-Star II refit can get underway with one of the apprentices getting to grips with the deck beams and other repairs needed to be done on this Classic sailing yacht.







    This small motor launch is now finished and over the weekend will be going back to its owner so he can use it on the local rivers









    Another new project boat has come to the boatyard to be worked on and get restored back to its former glory and back on the water where she belongs







    The Morgan Giles 30 now sanded down on the starboard side and now just the port side to do and then it can be left to dry out and then it can get Gel Shielded as part of its refit.





    Next week there will be a start made on the Mai-Star Class dinghy to get it finished off and on the water and also the GRP dinghy will be started to be moulded.

  27. #27
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    Default Re: Spring work down at the boatyard and workshop

    The port side is now done so it is just a matter of time before it will be time to coat it in a new coat of Gelshield epoxy treatment



    Just the front edge of the keel and the back edge ahead of where the rudder sits and a long the bottom edge of the keel to sand back.







    The headlining panels for the Hardy 25 now cleaned of the old glue and made ready to cover with new material







    There are just a few panels to do 8 in total.





  28. #28
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    Default Re: Spring work down at the boatyard and workshop

    Using the old carpets as patterns cutting the new linings a little over size



    Just laying the linings into position to check size and shape before gluing them in position







    Starting with the two carpet linings on either side where the helmsman and navigator seats will be fitted after the linings are glue in position







    Refitting the centre bilge pump raiser pipe to the new diverter which will in turn be fitted to the forward cockpit bulkhead.





  29. #29
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    Default Re: Spring work down at the boatyard and workshop

    Trying to source parts for old bilge pump, thankfully the bilge pump is still made and is showing no sign of going out of production as time soon.



    On a completely different view, the way the Morgan Giles 30 stemhead fitting under deck fittings was glassed in after the deck fitting was bolted down and as covered up the fixings holding it in position.







    The deck is now starting to come apart, working from the transom and working forward along the hull to deck joint finding that it was held together with hard filler which as broken down over the years along with the fixings that held it down on to the hull.







    The apprentices are carefully removing the filler and cleaning up the joint to ensure that the joint is sealed with a more reliable and flexible jointing sealant which will not leak in future and with next bolts holding down the joint to ensure this happens







    The forward bulkhead in the Hardy 25 under the cockpit sole have to fit the new two diverter valved for the toilet and bilge pump.





    Just lining up the bilge pump pipes to know where to bolt the valves to the bulkhead





  30. #30
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    Default Re: Spring work down at the boatyard and workshop

    Sorting out the two halves of the centreboard case so I can line up where to put the biscuit joints to make up the total height of the case.





    From the build plans the shape and size of the case when it is in the dinghy once it is glued and nailed together and the inside is painted with epoxy to seal the surface of the centreboard for the life of the centreboard case.







    Reshaping an old centreboard from another dinghy which was no longer needed so it was reshaped to make the centreboard fro this dinghy







    All dry fitted and ready to be taken apart and ready to glue together





    The centreboard slot in the dinghy ready to fit the centreboard in with bronze wood screws in the traditional method of fitting centreboard case on a good bed of sealant and caulking cotton.



  31. #31
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    Default Re: Spring work down at the boatyard and workshop

    The first layers of CSM glassed on to the inside face of the chain locker bulkhead , then there will be four more on the inside before it is all flow coated and then the area in the chain locker well will be glassed in the same manner and that will be flow coated as well to ensure the whole area is watertight



    The pipework for the sea toilet and holding tank re-instated as before and the diverter valve fitted to bulkhead so it can be operated easily when changing over from overboard to holding tank when going from sea to inland waterways.







    The two pipes now cut to length in the toilet compartment ready to be connected once the rest of the work in the toilet compartment is completed.





  32. #32
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    Default Re: Spring work down at the boatyard and workshop

    The centreboard is now dry fixed together and the ribs are cut to fit the centreboard case over the slot



    The centreboard case needed a few pieces planing on the bottom edge before it would fit down on the hog.







    Finally it is now sitting down on the hog and is ready to get the screw holes drilled in the hog to be able to screw the centreboard case into the boat and the the centre thwart can be fixed back in position.







  33. #33
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    Default Re: Spring work down at the boatyard and workshop

    Over the past couple of days it as been possible to get the deck off the hull and clean the joint between the two halves and remove the old hard sealant which was between the two halves.Now that the sealant is removed and the joint as been sanded and new fixing holes have been drilled and countersunk for the new bolts it is time to bolt the two halves back together on a non hardening sealant which will move with the movement of the yacht and stay sealed.


    Once this job is finished the inside of the yacht can start to go back together with the new bulkheads and chain plates going in first along with the other smaller bulkheads that were find to be rotten in the cockpit locker area which will have to be put back in before any work can be done in the aft end of the yacht and in the cockpit area at all.


    So there is a long way to go to get the first of the refit sorted, but with patience and experience the job will come together in a good order.

  34. #34
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    Default Re: Spring work down at the boatyard and workshop

    Hi,
    Just had a week off from work, well needed as working hard getting right up to the break. Now it’s time to get back and get the work out of the workshop for the end of next month for the bank holiday at the end of May. Just had an enquiry for another re-decking job on a Finesse 24 and other small jobs over the summer. So I got a busy few weeks and months ahead if the deck job enquiry comes in.

  35. #35
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    Default Re: Spring work down at the boatyard and workshop

    Quote Originally Posted by jstarboats View Post
    Another project speed boat as come to the yard to have some bottom repairs around the transom area and a new lower transom repair before being painted and have its 2.0 litre BMW engine refitted and put back in commission

    [/CENTER][FONT="]
    [/FONT]

    Any updates on this one? I'd love to see more of the restoration/repairs/drivetrain.
    Tom

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