Winter seemed to be reluctant to leave the Chesapeake this year. The warm weather will stay eventually. In the meantime, this late winter season has been a busy one. As you can see from this month's reports, the "off" season has been anything but.
We’ll start with a detailed report from Caitlin Sims at North Point Yacht Services in Annapolis, MD. “A Pursuit 3400 Fisherman came into the North Point Yacht Services shop with a request to repair a five-foot-long delaminated area on the bow and repaint the hull, but once we started the repair, the objective changed quite a bit. The original damage was caused by a thru-hull drain from the anchor locker leaking water into the balsa core. The owner assumed that the damage was in the area clearly affected by the water, shown by paint failure and known wet core.
“We began the repair by removing the outer fiberglass skin of the front third of the starboard side of the Pursuit. At this point, it became very clear that the damaged area extended much further aft than previously thought. Fortunately, the balsa core only extended down to the water line area, which kept all of the core damage above it and kept the repair smaller than it could have become. After we saw how far the water had traveled in the core, we decided that the best plan would be to remove the entire starboard side skin and replace all of the core. We felt that this would be a more time-efficient approach and ensure the boat would have no more core issues in the future,” she explained.
“After the skin was removed, we sanded down the inner skin and found that it was all in great shape. Next, we laid in fresh balsa core with West System epoxy. Since we had removed the entire skin, large sheets of balsa could be used which saved a lot of time. While we were installing a new core on the starboard side, we also wanted to protect the core on the port side. We found it all to be in very good condition, but we knew that we could do better. The balsa core around every thru-hull was removed and replaced with a Coosa board, which cannot absorb water. This process was done for every thru-hull fitting above the water line. The next step was to begin laying fiberglass over the balsa. We used bi-axis cloth with matt for the strongest and fairest layup. Once multiple layers of fiberglass were laid up, it was time to begin the fairing process.”
“The first round of fairing was done with West Systems since it would chemically bond with the epoxy in the fiberglass,” Caitlin continued. “After that, we switched to Awlfair and began the laborious task of sanding. We got the starboard side of the hull fair and sprayed a couple of coats of Awlgrip high-build primer. Getting the starboard side to be one color really helps show where you are in the fairing process. After we were happy with the result of the high-build and the lows were filled, we painted the entire hull in Awlgrip 545 primer and did the final round of fairing.
“The topcoat color was Awlgrip ‘Heartbeat Grey,’ which was a custom mix done by Kellogg Marine Supply for us. We paired the topcoat color with an Awlgrip ‘International Orange’ boot strip and a clear coat over the entire hull for an added layer of protection. The bottom will be finished in black Pettit Trinidad HD. Overall, this project grew substantially from what entered the shop,” Caitlin concluded, “But the team at North Point Yacht Services was able to step up to the task.”
Andy Dize of Roudebush Yacht and Engine works in Dundalk, MD, has had a busy winter. “Hope all have stayed warm this past winter season. Even though the cold weather has limited our exterior facility improvement and repair efforts, we are looking forward to the 2025 boating season. For our current repair projects, the Sea Otter 18 refurbishment is moving into the mechanical and electrical hook-up phase. The existing transom reconfiguration has been completed to accommodate the 150-hp jet-ski propulsion plant.
“For the topside repair of a 28-foot Chris-Craft Heritage Express, we have completed the fairing and primer process in preparation for a Flag Blue Awlgrip coating of the hull sides. A new project we have secured is a contract to build two new 28-foot aluminum workboats for a local dive construction company. They will be powered by twin 150-hp Suzuki outboards. We are in the planning and design stages of this project. The tentative construction start date was mid-February with completion of the first boat in about four to six months. Another avenue of future work we are pursuing includes support efforts for workboat repair, maintenance, and dockage. It looks as if we are off to a good start for 2025. For your upcoming boat repair or maintenance needs, please reach out to Andy to discuss your project. RY&EW can support boats up to 44 feet long in our climate-controlled building.”
Smokey Glover from Lake Assault Boats in Portsmouth, VA, reports on the commissioning of the Smith Mountain Lake Fire and Rescue Boat. “It is a Brand New 2025 28-foot aluminum monohull center console with a powered landing craft ramp on the bow, portable davit, and twin Yamaha F300DEC outboards with Sea Star power steering. The full electronics package includes VHF and tactical radios, multi-screen radar/sonar/ navigation multi-function displays and a FLIR camera. Other equipment includes a 1500 gpm Darley fire pump driven by a marinized 5.3L GM V-8, a remote-control fire monitor, foam flotation, Awlgrip paint system, and a custom Boatmaster commercial triple-axle trailer. The hull was fabricated at the Lake Assault Superior, WI, facility, with all painting, outfitting, and commissioning done at the Portsmouth, VA, shop.”
Jake Glover of Ferry Point Marina in Trappe, MD, checks in with the following update. “The painters have been working through several winter projects. A 28-foot Tidewater received an all-over hull Awlgrip application, while a 23-foot Regulator had her hull sides done in Awlcraft. We’ve had a custom 38-foot Chesapeake deadrise and a 55-foot Jarret Bay, both in for significant winter work lists. The mechanics stayed busy with winter service work as well as their lists on the deadrise and Jarret Bay. Cummins and Yamaha repowers have been underway. Keep in mind Ferry Point now has two certified Yamaha master techs.”
We’ll finish up this month’s reports with an upbeat summary by Alex Schlegel of Hartge Yacht Yard in Galesville, MD. “We have had a good year, the busiest winter ever, and spring promises to follow suit. This winter has seen our nine indoor spaces filled with all sorts of projects. In one shop is a Mathews Brothers 22 having brightwork and engine maintenance done, a Little Harbor Whisperjet 38 also having varnish work and other repairs, a Morris 36 for deck paint and all deck hardware re-bedded, and a 2005 Eastport 32 having a pair of Volvo D3s replaced by Yanmar 4LV250s. While the engine space was open, we added sound insulation and baffles to the air intake to help keep water out. Also, a new instrument panel was made and dual station controls were installed. We ran autopilot hydraulic lines, installed a new refrigerator, put shaft seals on rudder and drive shafts, and removed the generator but left the wires and hoses in case the owner changes his mind, or a future owner wants one.
“On a 1985 Beneteau First 38, we peeled the wet and blistered bottom and re-laminated with vinylester resin, faired, and painted it. The painted sides were polished, the transom was repaired and repainted, and there was some re-bedding of deck hardware. We also did some thru-hull work, new air conditioning, new holding tank, new electronics, new overhead liner, a new folding propeller, and more. In our carpenter shop, Ernie Stuermer is making Honduras mahogany panels, windows, and screens for a 1950 Trumpy’s cabin side. We are also refinishing a salon desk made of mahogany but stained walnut to blend in with the walnut woodwork in the salon. There is a custom 30-foot center console having rub rail and deck work done.
“Last fall saw ongoing work on a 61- foot buyboat, including deck repairs and painting. We also did rub rail work and built and varnished a custom helmsman’s stool and a small cabin top repair, along with painting and varnishing. The owner’s friend, with a similar sized buyboat, the Nellie Crockett, stopped by to take a look. Both boats’ home port is on the Sassafras River. A 61-foot Hatteras was in our shop primarily for paint repairs to the starboard hull side, corroded aluminum transom windows, door frames, and hardtop supports. We removed the hardware from the brightwork on a 54-foot Rybovich Yachtfish so that Peany Matthews could do a better job on the varnish. Peany has been working here since 1979 doing beautiful brush paint and varnish work. He is so valuable that we created a shop just for him. Rybovich of West Palm Beach, FL, is well known as a high-end sportfish builder. This Rybovich, built in the 1950s, still looks perfect. In our paint bay is a 51-foot Hoek getting hull and mast paint, electronics, new batteries, and an endless list of improvements.”
As you start your spring commissioning work, remember that the air gets warm faster than the water so be careful, and don’t forget to recycle your used shrinkwrap!
By Capt. Rick Franke