Jabberwocky to GTR :- Survey & Sanding

Before completing the purchase and getting to work we commissioned a survey. This step is a must for older boats and is the only way to fully understand the cost of the restoration work which you are going to undertake. Further to this it will be hard to secure insurance for the ship when are are ready to launch without the backing of the marine surveyors report.

It was a nervous time in the process, now that we had committed to the rebuild it would have been heart braking to get a report which highlighted issues that were outside our control or budget. While the hull damage on the exterior was obvious to see it was hidden issues that would be the only thing to stop us now.

After a solid day reviewing both the hull and rig the verdict was out. While to report was lengthy and put the amount of effort required on to paper for the first time, which was a little scary in itself, there were only two new issues which we had not already factored into our plans. The first replacing the bottom rudder bearing and the second, medium levels moisture in around fifty percent of the hull. After talking to the surveyor and the owner we decided that as there were no external signs of osmosis (blisters on the hull caused by internal moisture) we would completed the sale and get to work.

The current owner was really helpful, he understood what the team was planning and also wanted to see the boat racing again. One of the most important steps to our successes was agreed as part of the purchase, the owner allowed us to use his yard and shed to complete the rebuild. The use of the shed was a massive positive, enabling us to work through the cold and wet months of a Belfast Winter.

 So with the survey behind us, purchase completed, shed at the ready our to do list agreed :-

• Complete Gelcoat restoration on all external surfaces, drying the hull out were possible.
• All running rigging to be replaced as it is older that 10 years, ensuring all spreaders, chain plates and fittings are secure with appropriate backing plates.
• Stanchions should be refitted with appropriate backing plates.
• Replace lower bearing in the rudder shaft.
• Replace electrics and burnt out wiring.
• Engine to be fully serviced.
• Spinnaker Pole to be repaired or replaced (current in two halves).
• All safety and navigational equipment to be replaced as per IRPCS Colregs.

all that was left to do was to get to it. 

The first and most time consuming job of the whole process was sanding down the entire hull. As we intended to dry the boat in the shed we had to remove the epoxy from below the waterline as well as fairing in all the top sides and smoothing out the desks. 

The first few days were full of laughter and optimism even if progress was slower than what we had hoped. A key learning for me at this point was to ensure you had the be best tools, no matter how slow your progress seemed it would be slower without them. 

A man's best friend at this point is a high powered random orbital sander with speed control. This tool was 2 to 3 times more efficient than a standard sander, when fitted with the correct grade sand paper you can easily switch from fast removal to fine finishing. The second tool of champions was an air powered sander with optional attachments. This allowed us to get into the corners and tight spots, easily controlling the speed through the gun driven compressed air sanding head. 

With all of the team working full time we only got together to work on ship on Sundays. Even with a consistent group of 4 to 6 putting in 6 to 8 hour each weekend the strip down and sand took over 3 months. While it was a little discouraging that it took it a twice a long as we planned the team was still in high spirits and in complete agreement that it was best to take our time even if it resulted in us missing the start of the 2014 season.

A couple of me best memories of this part of the process were :-

• The BBQ's that we would have in the rain on a Sunday afternoon. Siting around eating while covered in dust were strangely satisfying. No matter how far behind we got we always ended with a smile on our face as we discussed all the wonderful plans we had with full bellies.
• The day I realised we really needed to hurry up and complete the first task so we could get her inside. I spent the first hour of the day chipping ice off the deck before blow drying the last areas that needed sanding. It was time consuming enough removing gelcoat without taking 1/2 and inch of ice off first.

Towards the end it did become a time V perfection decision, we all wanted a top quality finish but filling every bump in a boat that had already lived and raced for 20 year was going to be hard. After a long debate on a cold and rainy December day we agree that while we would make her shinny and new that a few bump would remind us all of the life she had already lived. So with this final thought it was off to the shed to start the drying processes and to work on the inside.

Inside to Dry

To watch the full rebuild from the start, click the Play button below.