Replacing the rotten wood

As we mentioned a couple of weeks ago we found another leakage (click HERE) that we thought was in one of the hatches and the water had found is way down to the plywood below where it got stuck due to the styrofoam placed on the plywood. As mentioned in the other post our hull is sandwich material, but the core is not wooden in the structural parts of the hull. And from the aft cabin a part of the hull can be seen, as the deck continues in under the cockpit. The cockpit is then kind of built on top of the hull. Hard to explain, but the point is that we can feel the edge of the hull and it feels really strong.

To the left – a part of our deck and to the right – our hull below waterline. The red part is just plastic (according to some documentation we found the outer part of the sandwich hull is classified as strong enough for this boat), then a synthetic core material and finally a last layer of plastic. So it is pretty thick hull.

But the more we have started removing the rotten wood we have found weaknesses and also the leakage, or at least one of them. The leakage is in the starboard hatch in the cockpit wall and right next to our starboard winch and a mooring bollard. And at some attachments the plastic is really, really thin. So we will not only repair the leakage but also reinforce this part. On port side we don’t seem to have the same issue, but maybe we will do some reinforcements there as well, just in case.

Working on removing the rotten wood in the roof in the aft cabin.
Rotten wood, as you might imagine, the smell was pretty bad…
It was also very wet and we are working hard to get this part dry with a temporary fix for the leakage (duct tape, yay!) and using a cabin heater.

Some water had also found its way down to the wall between one of our big hatches in the cockpit and the aft cabin. Probably some water had been standing in that hatch and made the wall between rot. There was an old drainage hole into the storage under the aft bed that was sealed. We removed the rotten part of the wall to replace with new fresh wood. We also drilled a new drainage hole from the storage hatch but this time we drilled it in direction towards the bilge instead of into the storage.

Removing the rotten part of the wall between one of the storage hatches under the seat in the cockpit.
Bye bye, rotten piece!

We cut the beam that followed the hull further up and the wall it self below so that the cut wouldn’t be at the same place. This way it becomes stronger, which will be good even though this is not what holds the boat together.

Making new pieces.
The beam in position, seen from inside the aft cabin.
Same, but this time seen from the hatch in the cockpit. Here you can see that the beam was cut further up than the wall. If you look really closely you can see the new drainage hole in the corner at the bottom.
Now we just need to paint this wall to make it look nicer and to protect it.

Will try to make a new blog post soon again, we have been pretty busy with a lot of stuff and also we mostly been finishing the interior work, so not so much new stuff anyway. We are very, very soon finished with that so at that point we will have some before and after pictures to show and we will also start with other jobs.

Making roof panels for sailboat

After we have finished with the mahogany strips we started making roof panels so that the roof would match our beautiful new mahogany.

We bought a fake lather boat interior material at the boat store. We choose to buy the thinest version of the material, which was 1.2 mm thick. The reason for not choosing a thicker version was that the surface we want to attach them onto will be pretty smooth and then there is no need to have a thicker, more forgiving material.

preparing for roof panels on sailboat
First we have glued up pieces of wood onto the roof, which we will attach the roof panels onto.
Next step is to fit the plywood and cut it in the rights shape. We have used plywood that is WBP treated (weather and boil proof). We used 7 mm thick plywood so that the roof panels will be firm, if using thinner plywood it could start loosing it’s shape and start hanging and that we didn’t want. This thickness we choose feels very stable right now and hopefully it will stay that way.
Then we made an edge and fixed it with glue onto the plywood. And spend some time sanding it to have a smooth edge.
Next up is to glue the fake leather fabric onto the plywood.
This is the glue we have used. It is used for gluing bathroom carpets so very good for humid areas.
boat interior material onto our roof panels for the sailboat
Attaching the fake leather onto the plywood and making sure that there is no irregularities that will show later.
Finally we attached the edges with staples.
spotlights roof panel sailboat
We have also bought some spotlights we added onto the roof panels. Nice to be able to light the boat up ๐Ÿ™‚
roof panels for sailboat
Some roof panels waiting to be set up in the sailboat! ๐Ÿ™‚

Now we will just have to set up all the roof panels in the sailboat and after we are finished with that we are pretty much done with the interior (except some final fixes around the freezer and our fixes for the wood that was damage by a leakage). At least we want focus so much more on that right now before our departure but there are still a lot of things we want to improve but that will have to wait until the future.

We have also recently worked with repairing the damage done by the wood that was rotted, working with the freezer. More about that soon ๐Ÿ™‚

Another leakage found…

Last weekend when we, as usual, were at the boat working we noticed a new place with rotten wood and apparently a leakage from above. We found it when we were removing styrofoam in our aft cabin (see The Boat to see an overview of of our boat). This rot is underneath one of the seats in the cockpit an dour guess is that it is a leak in one of the storage hatches in the cockpit (were we didn’t add any new plastic during our big plastic repair job). But, this is something we will have to do later in the spring. Yet another thing on the to-do list…

But, of course we are gladย  that we remove the styrofoam so that we find these things and can do something about it before we leave. We are also really glad that our sandwich hull does not have a wooden core (it is only above the waterline we have some places were there is a wooden core).

But some good news is that we are almost completely finished with setting up all mahogany! ๐Ÿ™‚ And it looks so good, Thomas has been very thorough and it really shows. We have also started preparing for setting up som kind of roof panels, which will make our boat look even more fancy. We also plan to set up some LED-lists to put some light on our new hull and to get more light in the boat.

So soon we will be able to show some really amazing before and after pictures. We have also made a slight change of plan when it comes to our sailing route, but more about that soon as well.

Our boat is starting to look fancy!

We are definitely starting to make a progress with our mahogany interior. And the result is really good, we are really happy with our decision to do this work, even though it takes time. It both looks really good and also a lot of improvements with the boat smell. The entire boat is bit by bit starting to feel a lot fresher. One thing we did that has been a huge improvement smell-wise, is that we have set up old computer fans in the bilge to drag out the air in the bilge outside instead of it rising into the living area of the boat. We are also looking at renting a ozon generator to get rit of some old boat smell.

Now let’s look at some mahogany pictures.

Setting up some mahogany.
The final result! ๐Ÿ™‚
This is how it looked before, hard to show on a picture but the fabric was pretty worn out, had lost a lot of color and had gathered a lot of the famous boat smell.
And this is how it looked behind the old fabric and the styrofoam we got rid of. Very dirty and some mold as well. Really nice that we opened it up and cleaned behind.

We have planned to add mahogany at two more places, around the navigation table and at our aft “cabin”. After that we also have some more work to finish our electrical installation and also continue with our autopilot, of course. And also get all paperwork in order.

Mahogany progress

This weekend most of the time has been spent preparing for and setting up mahogany strips.

Plywood strips on the hull in the bow. Painted black so that any glitch between the mahogany won’t reveal the plywood behind.
Insulation material Armaflex between the plywood strips.

Armaflex above the chair we have on port side.

We have started to set up mahogany as well, but forgot to take a picture of that so it will have to wait a while.

We have also worked a bit with our gearbox. It has been leaking so we took it out and bought new sealings for it and did a more thorough job than we did before (when we had the engine out and did a renovation of it). When we have put it back and try it again it will hopefully not leak and we won’t get oil in the bilge.

It takes time to get all the mahogany strips in place and we will probably keep doing this for a while so sorry in advance for not so varying blog posts ๐Ÿ˜‰

But will prepare one soon about some insurance thoughts, which we have started to investigate. A conclusion so far is that it is not easy when you have a boat that is cheap. But more about that in another blog post soon.