I will be sailing to Exmouth in April next year, and I plan for the return trip approx. 2 weeks (to Freo), or 3...4 weeks if I stop at the Abrolhos Islands.
Distance is approx 850 NM.
You did not say how big the cat is, but lets say 40 ft. You should be able to
motor and sail at 6 knots.
BUT....... you are likely to have headwinds all the way to Perth/Fremantle, as SW to SE winds will blow at 20-25 knots, very uncomfortable and wet. I doubt if any recreational
boat (or crew) can do that at 6 knots for 800 NM.
When motoring into the
wind and waves, you will double the normal
fuel usage, you may need to refuel once or twice.
There are two options, sail fairly close to shore in the 50 to 200 mt
depth contour so you will be assisted by the Leeuwin
current, or tack out to sea for a few hundred miles until the winds are more westerly, and you can then sail to Fremantle on one tack.
One other thing, it is cyclone season now, check your
insurance and check the
weather, as really not many places to hide on that trip, only Carnarvon/Shark Bay/Steep Point and Geraldton. I would not go into Dongara or Jurien in adverse
weather. Even in Geraldton I would prefer daylight hours, and I know that area very well.
As you said, your husband is an experienced sailor, he would know all this.