Projects: Swiss Couple’s Boat Restoration Rescue?

After years of anticipation and diligent saving, ‘Ship to Shore’ finally took the plunge and acquired their first sailboat, a vintage Hallberg-Rassy 352 from the year 1984. Their extensive backgrounds in photography, theatre, and cultural management became the springboard for a dramatic shift in their lives. They traded the peaceful vistas of Switzerland for the lively scenes of Portugal, where they made their first marine investment, which would be the start of their boat restoration.

Initially, they had no grand designs of becoming full-time DIY boatbuilders. Their dream was to inhabit a boat to cruise open waters and undertake minor repairs when necessary. However, they found themselves residing in a shipyard for a whole year, engrossed in a comprehensive refit of their boat.

“Our primary motivations for boat building are learning new skills, gaining independence, and saving money by doing the work ourselves.”

couple in front of their boat made with west system epoxy

What’s the Current Project Underway? When Is It Expected to Finish?

Their greatest project, without a doubt, was the full refit of the deck. After stripping away the teak, which had weathered nearly four decades of wear and tear, they unearthed a startling revelation.

Moisture had seeped into the foam core of the deck. It was through the multitude of screws used to secure it in the 1980s. Once they extricated the screws and re-drilled the holes, they were faced with the painstaking task of waiting for the deck to dry out. “Imagine watching paint dry, but slower and with more anxiety.”

The climate in southern Portugal turned out to be quite beneficial. With its mild winters and dry summers, the conditions were favourable for drying a damp deck. Nevertheless, it still required nearly eight months, a protective tent over the boat, and the assistance of three infrared heaters before the moisture levels were deemed acceptable.

“We then filled every hole with thickened epoxy using syringes for better access. We had to cut out some inspection hatches to check the foam core, so we sanded bevels and re-laminated those hatches once they were no longer needed.”

Their next major task was to lay a layer of 450g/m2 biaxial fibreglass to ensure a complete moisture-seal, heeding the advice of the WEST SYSTEM® Technical Team. The most formidable part was the preparatory work. This included an amalgamation of relentless sanding, measuring, and pre-cutting any fibreglass/peel-ply. Taping the entire deck and setting up epoxy-mixing stations were also part of the process.

Unexpected Delays

The heat often restricted their working hours to post 4 pm, resulting in two-night shifts to lay the fibreglass over the entire deck. They then applied a layer of epoxy thickened with a 3:2 mix of micro balloons and silica to create a smooth surface, primed for the new synthetic deck.

“In the meantime, we’ve used our new skills to fix all kinds of problems on the boat. We rebuilt a locker lid, sealed old holes, glassed in a bilge drain plug, reinforced the rudder, and much more. Our confidence and knowledge have grown enough that when we identify a new problem on the boat, we can fix it within a few days.”

Their initial plan was to set sail in October 2023, but unforeseen circumstances led to a delay. They’re now pouring their energy into finishing the project, aiming to hit the water by autumn, or even earlier if things go well.

What Tools and Materials Are Key to Your Project’s Success?

During the early days at the shipyard, the consensus was clear: WEST SYSTEM Epoxy was the go-to choice. The team purchased their initial litre of resin plus hardener, not anticipating the subsequent need for nearly 20 more litres.

The WEST SYSTEM 206 Slow Hardener® became an invaluable asset in the warm Portuguese climate, providing additional working time. The WEST SYSTEM “Fibreglass Boat Repair & Maintenance” manual was a crucial guide, aiding in various repair projects and occasionally settling debates over specific repairs.

Their toolkit was comprehensive, featuring an ample stock of disposable protective gloves, wooden spatulas—like those employed by dentists—and mixing cups. Plastic putty spreaders were also part of their essential equipment, complemented by a dependable sander and vacuum for their tasks.

Did Anything Unexpected Happen While You Were Making It? How Did You Deal with It?

“One major challenge was the need to wait for the epoxy to become workable, as temperatures had to cool sufficiently. On occasion, this meant delaying work until 4 or 5 pm, a test of patience. The most significant setback was the prolonged drying time of the deck core. Despite using infrared heaters, there was a reluctance to raise the temperature, fearing it might ‘bake’ the epoxy. The WEST SYSTEM Technical Team’s advice was key in helping us overcome these obstacles.”

The pair encountered a steep learning curve with this boat project, often underestimating the preparatory work required for each repair. The extensive cleaning, sanding, precise fairing and careful taping exerted significant pressure on their already compressed schedule. Through these experiences, they have since adopted a more generous approach to planning, recognising that even minor tasks can demand considerable time.

Post-Restoration, What Are Your Plans for The Boat?

Frederik and Ariane have set their sights on a life at sea, charting a course to discover the world’s most secluded and breath-taking destinations. As a photographer, Frederik is keen on documenting the stark and isolated landscapes they happen to come across, while Ariane is enthusiastic about sailing through open seas. Their plan includes a transatlantic crossing from the Azores, with the possibility of extending their travels to Patagonia or Ushuaia.

What’s Next?

Frederik and Ariane are ready to sail on their boat. They’re planning to install a new electrical system, aiming to harness the energy of the sun and sea with solar panels and a watermaker. These upgrades are set to steer them towards a future of self-reliance on the water.

What Advice Would You Give to Anyone Else Looking To Build/Restore A Boat?

The pair expressed the importance of preparing for the fact that things may take longer than initially anticipated. Celebrating milestones, both big and small, throughout the journey. Keeping a variety of snacks readily available is always a good idea, and there should be no hesitation in seeking help when necessary.