Restoring 'Windsong' - Various Updates [Lots of Pics]

[Beersmith]

Updates:

Aside from the bulkhead repair and the cockpit sole repair, the other major repairs in the section I am working on (engine room, cockpit area) were to fill in many holes. I glassed in some holes at the waterline that will either be moved or not used anymore: the refrigeration heat exchange water thru-hull, and a hole used for the engine exhaust water vent loop. As mentioned previously, I filled in the cockpit area deck drain holes to modify their position. I also had a few holes to fill in the cockpit itself, including the large hole where the old autopilot control was, an old hole used for a telephone jack, and the hold hole where the autopilot control/engage cable went through.

Some of the holes required full build-up glassing, others (in the cockpit) required replacing the area with new core and glassing in. This job was a big pain as a lot of grinding, glassing and sanding was required. But as they were finally finished, I was able to paint necessary areas and give the rest a final cleaning to be done with this section.

With the engine room, cockpit area & quarter berth complete, I will now move to the front of the boat and work my way back. I wanted to get the first two sections done because they were somewhat more complex than any of the other sections, with more involved projects that I wanted to get out of the way. I will now work my way backwards so that as I clean the bilge areas, the gunk will flow down-hill.

Updated list for this section:

Deck:
-Remove all deck hardware – COMPLETE
-Pot thru-deck holes with epoxy – COMPLETE
-Thoroughly clean with soap, then solvent – COMPLETE
-Sand with 150 grit – COMPLETE
-Fill/repair all unused holes – autopilot, old telephone plug, etc. – COMPLETE
-Grind/bevel all dings and imperfections (including deck joint) – COMPLETE
-Fair decks with thickened epoxy – COMPLETE
-Sand fairing compound down to a smooth surface – COMPLETE
-Re-Apply fairing compound and sand down as needed – COMPLETE

Hull sides & Transom:
-Remove all hardware, thru-hulls & equipment – COMPLETE
-Glass in old drain holes – COMPLETE
-Thoroughly clean with soap, solvent, then On/Off where needed – COMPLETE
-Wet sand gelcoat with 600 grit – COMPLETE
-Sand cove stripe with 220 grit – COMPLETE
-Repair any dings in gelcoat – COMPLETE

Engine Room:
-Remove all hardware, wiring, plumbing, thru-hulls etc. – COMPLETE
-Wash all surfaces – COMPLETE
-Pressure wash bilge – Waiting to finish up-hill bilges
-Repair cockpit sole from underside – COMPLETE
-Glass in unused thru-hulls – COMPLETE
-Rough sand all surfaces – COMPLETE
-Clean sanded surfaces with solvent – COMPLETE
-Paint ceiling with BilgeKote – COMPLETE
-Sand gel-coat surfaces up to 600 grit - COMPLETE
-Varnish Trim - COMPLETE
-Add sound/engine room insulation (this will wait for later)

Quarter-Berth
-Thoroughly clean all surfaces with soap & water (pressure wash lockers), then solvent - COMPLETE
-Paint lockers with Bilgekote - COMPLETE
-Sand gelcoat surfaces to 600 grit - COMPLETE
-Varnish trim - COMPLETE

Without further ado, here are the pix...

Cockpit holes pre-work. On the left is the auto-pilot clutch control, on the right is the auto-pilot control unit.



Ground out a bevel, ready for new core and glass:



Control unit hole cut to fit in new core:



New core in, glassed in:



Glassed in, final fairing from the outside:



More cockpit holes:












Core cut and filled with epoxy:





Waterline holes:



Glassed in:



Cockpit drain holes:

[Beersmith]

Cockpit sole, post repair, pre-paint





Post paint:





Engine room - mostly equipped



Post engine removal:



Pre-cleaning:



After first cleaning, pre-sanding:



After final cleaning, paint, and sanding:





Quarter berth, post clean, paint, sanding, and varnish:

[barnakiel]

How do you get to the point where all items on your list are COMPLETE?

b.

[Beersmith]

Originally Posted by barnakiel

How do you get to the point where all items on your list are COMPLETE?
.

lots of time and hard work? not really sure what you are asking

[Cheechako]

Wow.... bravo man! Curious... why eliminate the cockpit drain scuppers?

[Beersmith]

Originally Posted by Cheechako

Wow.... bravo man! Curious... why eliminate the cockpit drain scuppers?

I haven't eliminated them. I replaced the entire cockpit sole core, so what you see in the pictures are the cockpit scuppers not re-cut out yet.

If you are referring to the deck drains, I am moving them lower than the current drain holes. The existing ones are at the same height as the actual deck drain fixtures, so nothing drains out of them unless the boat heels. This makes it so water is standing in the hose from the deck fixture to the drain, also filling with gunk. I will lower the drains so the hose from the deck fixture to the side drain is at an angle and will therefore drain at all times.

[barnakiel]

Originally Posted by Beersmith

lots of time and hard work? not really sure what you are asking

That's it. Lots of time, hard work. Perhaps the boat in the shed too.

I am impressed.

Unfortunately, my own lists ... as soon as the top items are COMPLETE, there will always be some new items at the bottom. A never-ending story ;-).

b.

[Beersmith]

Originally Posted by barnakiel

That's it. Lots of time, hard work. Perhaps the boat in the shed too.

I am impressed.

Unfortunately, my own lists ... as soon as the top items are COMPLETE, there will always be some new items at the bottom. A never-ending story ;-).

b.

indeed! Don't get me wrong, each of those "COMPLETE" things on the list actually contain 10+ sub projects that needed to be done. Every project on this boat opens up a can of worms that I need to take care of before moving to the next. Just the way it goes