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Old 08-11-2018, 11:43   #46
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Re: Southerly 480 - Build Thread?

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Looking Awesome!
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Old 10-11-2018, 05:29   #47
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Re: Southerly 480 - Build Thread?

I've written some background information on the buying decision,process and spec over on the www.southerly480.com blog site for those that may be interested. If there are any areas where you would like to see/read more detail let me know here, or by using the contact button on the site.

Having never done this sort of thing before, I'm aware I might be missing the mark, so direction is welcome
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Old 14-11-2018, 08:58   #48
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Re: Southerly 480 - Build Thread?

If I may, can I request some photos of the planned(installed) headliner, light fixtures, and the methods in which they are fastening the headliner?

Is the decking solid glass or cored?

I am in the process of redoing some wiring in my boat due to having to replace the headliner. Figured it's all open and exposed, might as replace what i can with new.

I like how the build is coming along!
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Old 14-11-2018, 11:13   #49
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Re: Southerly 480 - Build Thread?

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Originally Posted by chowdan View Post
If I may, can I request some photos of the planned(installed) headliner, light fixtures, and the methods in which they are fastening the headliner?

Is the decking solid glass or cored?

I am in the process of redoing some wiring in my boat due to having to replace the headliner. Figured it's all open and exposed, might as replace what i can with new.

I like how the build is coming along!
Hi Chowdan,

The decks are cored with Divinycel except for areas of high load/stress and where glass or ports are installed. There are also some beams that are moulded in to spread high loads around the structure, and I believe in the are under the mast foot/"windscreen" area this include carbon fibre for additional strength.

The headlinings are quite a process that produces a very good finish, but also allows panels to be readily removed should access for maintenance be required.

It starts like this



If you expand this you will see small pads of ply bonded to the deck head. These have Tee Nuts screwed into them, a length of threaded bar is screwed into the nut, and normal hexnut is added. The board is then positioned onto the bars, and its position altered by adjusting the various nuts to get the right alignment, shown here with wing nuts during installation.

These boards will cover all the areas to be lined. Here's the next one to be installed in the fwd heads



In some areas with curves the boards are omitted, and pads are bonded to the surface with the lugs in place for the next stage like here in the aft cabin



So if you look at the rightmost pad, you will see a plastic hex shaped fitting. This is the female part of a pair. The final board that is covered with whatever material is chosen is then fitted, and held in place with these fittings as in this picture, whilst secure they are a press fit so the panel is easily removed. Here are some fitted prior to being covered.



I don't have any close-ups of the fittings, but I will get some when I visit next time, and add them to the post.

The light fittings haven't been installed yet, so again I will add pics when they are, but they will be round LED units, which I guess will be like domestic types with sprung legs to hold them in place, and a simple hole in the headlining board.
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Old 14-11-2018, 23:24   #50
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Re: Southerly 480 - Build Thread?

This week’s visit has made me quite excited! There were a lot of people working on different aspects of the boat, and of course my job is to keep out of the way, however….

Up above I’m pleased to say the main companionway has been cut out, so now the rest of the glass is being fitted. Its good to see some of the removed bits of GRP, it gives a good idea of how thick/strong the mouldings are



Aft deck lockers are now being completed with liners and lids being aligned and fitted and made ready for the decking.




Now that tabbing is complete, the steering gear will be fitted, and the whole lazarette area treated to a further coat of flow coat.
So the companionway hatch and washboards are now functional, and the hatch garage was waiting to one side ready for installation.



Winches have been installed with protective wrapping, through the sheet bin aperture, you can just see the label of the electric motor unit.



Clutches are in place but wrapped, so next along the overhead saloon hatch and fixed port is being installed seen here from the inside with the framing for the finishing’s being installed



Whilst at the bow end the pulpit was going into position, this has fold down seats for those occasions when it’s nice to sit at the bow. You can also see the pad for the windlass in position. These pads are used to avoid bolting components through the (teak/synthetic) decking.



The mast step will be installed shortly, when the compression post goes in later in the week, they had been checking the delivered part, so it was sitting on the deck.



It felt good to be able to go below through the main companionway albeit on temporary steps, and below there has been a lot of progress, with a lot of the headlining panels fitted, yet to be covered with the Silvertex lining material. Here are the steps:
Firstly supports are positioned



Next the liners are fitted



Then these are covered/trimmed and the final article will look like this shot of the forecabin hull ports, with a blind installed to check the design detail works well



You can see more of the boards in this shot of the nav-station, and the headroom in the saloon area which is still very good when the headlining is in place.



Much of the flooring is currently temporary boards put down since the flooring panels, now cut out and trial finished are being sent back to the joinery department for the Amtico to be applied, and for the boards to be sealed/lacquered.



Lastly more preparation is being done to the swim platform, here’s the inside surface being prepared, the stainless cassette contains a folding ladder, and fits into the slot on the top edge of the door on the far left of this photo.



Not pictured but a lot of other kit had been installed, such as the salt and fresh water pumps and heater matrices etc, but these are covered at the moment, so I will cover them in a future post when I can get to them. In the next few days the mast compression post, the chain plates, the final elements of the galley will be installed whilst the steering and deck will be largely complete ready for Dek King to do their stuff.
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Old 23-11-2018, 03:01   #51
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Re: Southerly 480 - Build Thread?

A week goes very quickly it seems! So this weeks visit saw an army of people working on different areas of the boat, meaning access was more difficult, however it was an eventful visit. Lang & Potter were there to take final measurements for the upholstery, collect some of the stainless fabrications, and discuss some of the finer details of the finish for the upholstery, plus it was a timely opportunity to double check the positions of some of the electronics, control panels and tv's etc. Most of this has standard positions which are fine, and largely agreed during the specification, however we did make one or two tweaks.

Here you can see the stainless supports for the saloon backrests resting in place for measurements to be checked



The open hatch in the seating is showing the location of a couple of auxiliary AGM batteries, and a Mastervolt Magic DCDC charger is just out of sight.

Overall the cabins are taking shape very well with the linings/headlinings nearing completion, here’s the forecabin showing the side-linings in place, and the head-lining support grids in position, and aligned, the protruding bolts are being snipped off ready for the upholstered boards to be clipped into place. The supports are made of a lightweight ply I was amazed how little a panel weighed given how strong it is.



The cabin sole boards are now back in the joinery area where they had been laid out on floor so that the Amtico “Dusky Walnut” flooring pattern could be marked out before the panels are fixed down permanently. I missed the main part of this, but there was some left in situ. In this photo you might just be able to see the pencil lines drawn on the wood to indicate the “plank” edges. When completed this will ensure continuity of the grain pattern and tiles right throughout the boat. On the right of the photo is the base for the seat for the forecabin desk area, which had been positioned on the floor to identify the mounting hole pattern. The squabs had already been collected by the upholsterers.



So here is one small panel covered with edges and backs yet to be sealed, when this is back in the boat the covering will be in perfect alignment with the adjacent panels.



So with the cabin finishes well underway, its good to see that the plumbing and electrical installations are also advancing rapidly. In the galley the sinks had been put into position, whist a couple of other components had been removed for the Corian work surfaced to be attached, prior to the installation of the main sections, whilst under the sink the plumbing is nearly complete. Here’s a dark photo showing the main Seagul IV filter in place. We had one of these on the last boat, and I have been very pleased with how our tank water tastes.



So next week the galley will be looking pretty much complete.

One of my favourite elements is just starting to be installed: Nav instruments. A bit early to show really but here’s the first box of the Raymarine kit we have chosen. This will be installed at the helm position, on the back of the cockpit table.



Meanwhile the engineering guys have begun installing the Lewmar Mamba steering system. In these two shots you can see the top bevel gear has been installed in the pedestal, and the input shaft ready to take the wheel, whilst the second shot shows the top UJ and torque tube in place. The lower end of this is connected to a further gearbox, and then to an arm fixed to the rudder shaft, being an amateur at this game, I messed up that photo, so will show that detail in the next post.




During the week the mast compression post, mast foot, and chainplates had been fitted. The chainplates are left on show in the saloon, so are nicely polished.



Off the boat, here is a photo of the arch being prepared for installation. Here you can see the stainless fabrication being clad in a GRP shell. The tube section is actually pipe thickness hence unpolished, and very strong, we did consider powder coating/paint rather than GRP, but on balance the finished item suits the boat well. So many choices…



Finally for this week a shot of the companionway steps ready to be installed in place of the temporary “build” steps

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Old 28-11-2018, 06:04   #52
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Re: Southerly 480 - Build Thread?

This week I only made a very quick visit to the factory since its only a few days since the previous visit, however progress has been made. On the outside of the boat more of the deck fittings had been installed, to the point where the decking can now be fitted. This picture shows the the foredeck area, with windlass installed, followed by one of the sail locker access ladder.




Here is the curved track for the self tacking jib with the mast step, and ventilator for the fwd heads to the left




Shown here are the stainless grab rails that have been installed on the coach roof



At the aft end the first elements of the decking are being installed. This may well divide opinion because its synthetic, and because its not teak coloured, but I'm pleased with how it looks, and looking forward to the ease with which it can be cleaned. It should also be a little cooler in the sun, and lighter as well.



Down below the companionway steps had been installed you can just make out the hinges under the top step. Although these lift up, all the daily check/service items are accessible through the floor or hatches in the aft cabin but for larger jobs these can be lifted, and a catch is provided to hold them up.



The teak surround has been installed at the top of the companionway



And the Corian work surfaces are now being installed in the galley. The colour (Ash Concrete) can be seen on the right hand side where the up-stand is not covered.



Meanwhile more progress on the head linings and boards has been made. Here's how the forecabin looks now



A lot of progress has been made on the wiring and I saw the beginnings of the NMEA2000/Raymarine stuff going in so hopefully I can get some photos of the electrical systems next week.
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Old 05-12-2018, 07:46   #53
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Re: Southerly 480 - Build Thread?

Well another week goes by, and so another visit to see the progress on the build. Lots of work has been done, with more head/side linings installed and with the LED light units going in at the same time. Here's the fore-cabin area above the desk area showing a couple of the Quick Lighting units, and the head linings in place. In the very top left you can just see one of the overhead deck hatches, which have now got their surrounds in place, and integral fly screens and blinds installed.



Underneath this area the first elements of the stainless steel trim were being installed in the fiddle rails, Here are some installed above the desk cupboards, with a couple of sections waiting to be installed at the base of the adjacent cupboards. At the lower left a couple of power sockets are being installed.



And some more along the shelf beside the fore-cabin berth.



The heads compartments are now very nearly complete with the shower door and mixer tap installed (with some festive tinsel) in this shot



On deck stanchion bases, rubbing strakes and the aft pulpit have been installed, in this photo the bow sections are being cleaned up and inspected for any imperfections. The cove line is shown here moulded in white gel, but will soon be covered in a stainless steel coloured vinyl tape.



In this photo the Raymarine I70s instruments were being installed in the hatch garage pod



Other elements such as the hull transducers, and Raynet HS-5 switch, and AIS are being installed now as well, here is the HS-5 switch and AIS700 unit installed under the nav desk.



At the stern the swim platform had been craned into position and the stainless hinges were being positioned. The blue object on the right is a stainless chain plate for the split back stay.



More of the steering system in now in place, this photo shows the torque tube connecting the upper bevel gears to the lower gearbox



The same components are present for both the port and starboard wheels and are linked by a tie bar shown here



While in the same area I took a quick snap showing the cockpit drain and shore power inlet socket installed with protective boards covering the decking material with a harness attachment point, and manual bilge pump covered in yellow tape. The white paper at the left top of the photo is covering a vent grill



Whilst underneath the waterline the four blade Maxprop feathering propeller and Ambassador rope cutter have been installed.



And the mainsheet arch was being finished with wiring in place for the cockpit lighting, sadly I don't think this will be in place for Dusseldorf since it nearly doubles the cost of the transport because of the hight and it's not easy to put up and take down



Over in the joinery area the floor coverings are now almost complete, ready for the edges to be sealed prior to installation



And on a different bench more stainless trim was being fitted, here the large fiddle that goes on the aft cabin berth is being addressed.



The last bit of the joinery which I had not seen previously is the instrument binnacle to be installed on the nav table seen here after being lacquered



So she is progressing very well, and I am very pleased with how she is coming together, can't wait to see her with all of the protective coverings removed! As I was walking between the buildings I saw one of the Bluewater 50 catamaran decks about to be transfered into the build area, and it reminded me how much bigger a 50ft cat is than a monohull, simply huge!

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Old 12-12-2018, 13:25   #54
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Re: Southerly 480 - Build Thread?

So this week when I arrived the factory doors were open and the scaffolding that surrounds the boat was being removed in preparation for next weeks transportation to Dusseldorf. So for the first time the hull was in direct sunlight, and I see the first bit of "chrome" vinyl tape has been laid over the cove line which was moulded in white gel.



Interesting to see how much lighter the grey looks in the sun compared to in the factory, here you can see the exhausts for the genset and engine, these are dry with the water exiting under the waterline



Whilst under the boat I noticed strainers had been added to the saltwater intakes for the engine, generator and saltwater circuit for the toilets and galley



Moving on up to the build floor, the ring deck has now been fitted, here's a shot taken before the final clean up of the caulking/detail had been done. The stanchions have also put in an appearance, with a temporary rope added for safety now the scaffold is being removed



The last bits of deck gear have been installed



And the I70s and waterproof USB charging point are now installed in the companionway



The steering compasses are in position, these will be swung by Robinsons as part of the comisioning process



Next to the compass the thruster, autopilot and main sheet winch control have been installed, as well as the keel control swim platform control and Halyard exhaust temperature alarm but these were obscured so I will add pictures at a later date.

Although completely obscured by protective material, the cockpit table is in place. This is the only raw teak on the boat, but we inevitably keep that clean anyway. The substantial handrail mounted on the table gives a secure handhold anywhere in the cockpit, and is a useful harness point in addition to the four U bolt types installed around the cockpit. On the end of the table is an Axiom Pro plotter, and emergency switches to turn off/on the electric power to the winches/windlass etc and a high power twelve volt socket.



So after going off for a coffee I returned to look below, the galley now has a cooker installed. Its a GN Espace Ocean Chef



And the microwave is in place



The main reason for the visit was to see Lang and Potter who had arrived to trial fit the upholstery, so the boat was very crowded, but here are a few shots. The stainless backrests, and cushions are just resting in place so not perfect yet, but good enough to judge the effect. Heres the fore-cabin berth with its very comfy pocket sprung mattress, backlit leather headboard, and in the lower left you can just see the charcoal leather backrest for the desk seat.



Unfortunately my phone can't get the whole cabin in one shot, but I am very pleased with how it looks. I will try and borrow my daughters SLR and get some better photos. Anyhow...

The heads is also looking complete with the Corian surfaces now exposed and the Tecma thrones installed



The shower side of the heads is also looking good



Here's the navstation area with the Charcoal leather seat, and in the background the Ray 63 VHF, and Mastervolt Easyview 5 panel being installed. There's a couple of 240v sockets next to the VHF, yet to have the chrome surrounds added.



Getting out of the electricians way because he was waiting patiently! Here's the main raised saloon area with the seating in place although not installed



The aft cabin.



There is loads of storage in this cabin, and more lockers under the tri-view windows can be ordered, we didn't in this case, because there is plenty as standard, even with the Side Power SE100 stern thruster, Mastervolt magic charger with serial interface, and Mastervolt Mass GI3.5 Isolation transformer plus two red flash batteries and a huge heating silencer. Heres the Thruster



Finally a visit to the joinery area to look at the doors and agree the stainless trim positions before the router is deployed. Heres a door without furniture but the effect is clear



I will do a quick visit next week to wave the boat off to Dusseldorf, and if there is interest I will take a few shots of the stand and boat as it appears at the show. Hall 16 / C42 I believe if anyone would like to visit. Again if there is interest I will be visiting the sail maker before the boat returns, and can post a few shots from there.
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Old 12-12-2018, 19:45   #55
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Re: Southerly 480 - Build Thread?

Absolutely gorgeous!
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Old 13-12-2018, 01:45   #56
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Re: Southerly 480 - Build Thread?

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Absolutely gorgeous!
Thank you for saying so, we're very pleased with the way she is coming together. Its great to see your Amel thread - She really is a very well thought through yacht, and a comfortable home too....
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Old 13-12-2018, 08:14   #57
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Re: Southerly 480 - Build Thread?

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Thank you for saying so, we're very pleased with the way she is coming together. Its great to see your Amel thread - She really is a very well thought through yacht, and a comfortable home too....
I decided on the Amel thread after I saw yours. You started a trend!
Except for the cost, buying a new boat and seeing it being built is exciting. Enjoy!!!
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Old 15-12-2018, 01:46   #58
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Re: Southerly 480 - Build Thread?

OK well I made an unplanned visit to the yard yesterday to fiddle about with the TV position and took a couple of snaps while I was there using an old camera rather than my phone. Pics came out very dark because I cocked up the settings, but anyway there are a few that aren't too dark, or suffering from camera shake!

Heres one of the aft cabin showing the headlining that has been installed



Galley area now has the flooring in place, and the handrails for the companionway steps have been fitted



Nav area is looking pretty complete you can see the heater controller and saloon thermostat under the desk, the Genset panel is now in place along with the VHF and Easyview 5 panel. An Echomax XS control is just hidden from sight by the Almanac shelf under the desk. Good to see the lighting is working, and one of the stereo speakers in the top left.



The cabin doors have been fitted for the first time, so here's a couple showing the door and door furniture. They have come out very dark, but good enough to see the effect




Heads are complete, and some cleaning up had been done, so heres one of the FWD heads so you can see the colour scheme



Outside the short rig for Dusseldorf had been placed on the foredeck, and the final few locker doors were being adjusted here's a couple that didn't suffer too much from camera shake!




By the time I left the boat was starting to be wrapped ready for transport to Dusseldorf, they will still have access to complete the cleanup and a few last jobs below.



So next week she will be pushed out of the factory ready for transport on Wednesday.
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Old 17-12-2018, 13:34   #59
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Re: Southerly 480 - Build Thread?

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Originally Posted by chowdan View Post
If I may, can I request some photos of the planned(installed) headliner, light fixtures, and the methods in which they are fastening the headliner?

Is the decking solid glass or cored?

I am in the process of redoing some wiring in my boat due to having to replace the headliner. Figured it's all open and exposed, might as replace what i can with new.

I like how the build is coming along!
Hi, Hope you got what you needed from the previous threads. The lighting units you asked after are from Quick Nautical. I managed to loose the picture I took I'm afraid, but they are 316 stainless.
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Old 18-12-2018, 00:22   #60
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Re: Southerly 480 - Build Thread?

Next time I see her will be in the Dusseldorf show. Discovery just sent this through as they close up the access hole in the shrink wrap, she will be taken out of the factory later today, and loaded on to the trailer...



Do come and say hello if you visit the show.
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