The idea of a refit after 10 years of cruising started to form a few years ago. Its genesis began with the idea of replacing our electronics with upgraded technology and the idea that our barrier coat on the bottom would be 10 years old, its guaranteed life expectancy. We were concerned about its longevity after the work done in Rio Dulce that compromised its integrity. So when thinking about these events the rest of the agenda began to fall into place. Our mast hadn’t been down in 10 years so a good inspection and servicing was a good idea and the projects grew from there.We started making a list of what needed to be done and what upgrades we wanted.
We always knew that when we reached 10 years of liveaboard cruising it would
be time for some deep dive maintenance and refurbishment. Our generator needed
a major renovation and the engine needed cleaning after our previous two year issue that I described in other blog articles. After
10 years we needed more than just an oil change.
In our original trip plan we had expected to be in other parts of the Caribbean by this time, not Cartagena. But, extra years in Rio Dulce, extra years in Bocas del Torro and so this is where we were. In retrospect it probably is one of the better places to do the work we planned. Materials can be shipped from the States although the costs are slightly higher than Panama. Labor is available and very reasonably priced with most of the skills and trades reasonably available. I have also found there are fabrication businesses that can manufacture pretty much anything you need at very reasonable prices.
The rented crane stepping the mast.
Around the time we came to Cartagena I started outlining a workplan on an excel spreadsheet of the tasks that we needed to accomplish, fleshed it out into greater detail, added tasks as they emerged and then started identifying who was going to accomplish each task. For the most part we would provide the materials, Cartagena would provide the labor. I have the spreadsheet appended to this blog article although I deleted the costs. I would provide them on request.
During the work we couldn’t live on the boat so we arranged for an apartment in the Manga neighborhood not far from Club de Pesca. Each day I took an Uber back and forth to the marina. I usually arrived shortly after 8 and left between 5 and 6. Sundays I usually arrived a little later. There was a little store across the street from the marina that served a local lunch everyday for about $3-4. It consisted of a bowl of soup, a plate of meat, beans rice, plantain in some form and a little salad. For a local place like that run by a couple of local ladies the food was very good and a good bargain.
Most days there were at least 2 if not 3 or 4 projects going on at the same time. It was a
fulltime job just managing all the work let alone trying to do tasks myself. One of
the perks we had negotiated with the
yard was to rent a small room in the office building that we could use for
storage. We rented it 6 months before we needed it and began moving stuff off
the boat into storage to facilitate other work we were doing. To remove the
generator we had to empty both cockpit lockers so all those things went into storage. We needed room to store the
sails and the line that we took off the rigging and as material arrived that we
purchased it had to be put somewhere. The stove and the crate with the galley
counters were large. The crate with the countertops had to be moved by forklift.
Doing this work without the storage would have been nearly impossible because
nothing could have been secured.
Very early after arriving I inherited a local laborer who was looking to do odd jobs around the boat. He had been working for friends who were leaving for 6 months. So, now he was looking for work and I had lots of basic tasks that needed doing so I struck a deal with him and engaged him on a daily basis. I never had a helper before but he became very valuable. Many of the harder tasks I avoided because I dreaded them so I had him do them. In fact, he didn't want me to do anything so there was more work for him which I was ok with. I had to tell him which screws to turn or bolts to undo. But, I wasn’t turning the screwdriver or the wrench and angling into tiny spaces. I paid him the US equivalent of $25 a day. He also had a car and knew where to get everything. I paid him extra for using his car.
Our car headed to Miami with boxes and buckets to ship to Cartagena.Not only did I use him to help me do a lot of difficult tasks, he was able to do mundane tasks for me that allowed me to call, text, email and analyze correspondence from contractors that I was considering to do the technical work or place orders for materials. For work beyond basic tasks he required supervision and identifying work for him every day imposed a discipline that allowed me to get tasks accomplished that I might otherwise ignore, delay or avoid. As a result, work got done that might not otherwise. Many of the tasks required two people so if I were doing them myself I would need to find someone. The bad thing is that it meant I really looked forward to the weekend so I didn't have to work. Just coming up with tasks everyday and supervise the work was work.
Our storage room started filling up as items began to arrive.Engine Maintenance + Upgrades
I've written much about our multi-year engine issue that we resolved in April of 2024. But, soon after it was resolved we traveled to Cartagena. Because we were in a hurry to leave, I didn't clean out the exhaust system as I had in the past. Additionally, after we replaced the thermostat there seemed to be issues with the engine running hot. So the engine issues were among the first area we attacked. For starters we changed the oil, the oil filter and fuel filters. Then we took it to the next level.
Tearing apart our engine with the turbo, the heat exchanger and the oil cooler all off.
We tore down the exhaust system and cleaned it. We removed the exhaust hoses, the muffler and mixing elbow and my helper thoroughly cleaned them, Then we removed the turbo, the oil cooler and heat exchanger cores. The turbo was new in 2022 but with the bad combustion it had gotten filled with carbon so I took it to the local injection shop who rebuilt it. The heat exchange and oil cooler cores I took to a local radiator shop that boiled them out cleaning them of contaminants and insuring their integrity. While the raw water cooling system was apart we cleaned out the cooling line through the transmission and those hoses were actually blocked from the salt water.
The hose connections going to the gear oil cooler were totally blocked by salt.I also replaced the thermostat gasket that I didn't do when I replaced the
thermostat earlier in the year. When I had the marina order the new thermostat I didn't
tell them to order a gasket and nobody reminded me to do that. Usually the dealer will ask if you want the gasket or maybe just send it. So I corrected that as the
old one was completely worn out.
Once everything was cleaned and rebuilt we reassembled the engine and filled it with water. I wanted to flush the system and check for leaks so I wasn't adding coolant yet. Once it was reassembled we found a few small leaks but we were able to tighten everything sufficiently and stopped the leaks. But, we didn't pop the champagne yet. More work to do.
The cleaned and tested cores for the heat exchanger and the oil cooler. The rebuilt turbo wrapped.I suspected that the engine gauges were not accurate and we saw many errors in them. So while in the States I bought new gauges and new sending units for the gauges to improve the information about the engine at the helm. Those gauges weren't completely installed so we couldn't really test the engine at that point. We ran it enough to find leaks but nothing more.
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Eventually, the senders and gauges were installed. A new "Stop" button was installed, the old one failing back at Shelter Bay last year and we were ready for tests. I ran the engine on 3 days up to operating temperature, adding water after each run and everything performed as expected. I drained the water out and added water again. Ran it over 3 days. Again, all was well. I checked the gauges with an Infrared thermometer to confirm the temperature gauge readings and they were always close. After the second 3 days I drained the water out and added a 50-50 mix of coolant and distilled water. After the third run the system was full. Next was the run to the Boatyard. In that run the engine ran smoothly, at temperature and provided more power than I've seen in years. The gauges worked well. So, now I need to keep the engine functioning well through continued maintenance.
Canvas - Replacement
When we bought our boat in 2014 it had no canvas on it because the previous owner really had no idea how to deal with a major cruising boat. So at the suggestion of our yard manager in Maryland we hired a local contractor who came up with some innovative ideas and put together a complete package of canvas that included a full enclosure, bimini top, hatch covers, winch covers and a pedestal cover. After cruising for the past ten years the clear vinyl is not so clear, the canvas is fraying and many of the zippers are broken. So it's time to replace. Over the years we've received many complements on our canvas layout with several boaters copying it to some degree.
The first task completed was our new sun cover. It's slightly larger than our old one to cover more deck space and to cover the companionway.With all this as prelude we pretty much knew what we wanted. To replace what we had. But we also needed more. The hard makralon panels in our dodger panels degraded from the sun so we wanted to add shades for them. The sun covers on our headsails were defeated so we needed those replaced as well. We also wanted to do some tweaking on other things to improve on small points. So with that in mind we began interviewing contractors.
Our new canvas and sail covers.Generator refit
About 2 years we began having issues with our generator. After I cleaned the heat exchanger the rubber end would not stay fast in place. I replaced the end and that seemed to fix that issue. But, I thought there was more to the story so when we made our plans I decided that I wanted to have the genset removed, thoroughly flushed with acid, sanded to remove the rust and repainted. In the process of interviewing contractors to do the work we discovered that the mixing elbow had broken at some point which caused a great deal of rust in areas that weren't readily visible.
The generator torn apart with cleaning and repainting already under way.
After interviewing several prospective contractors to do the work, I was unimpressed with their plans. Most focused on wanting to do maintenance at a very high price and the work we needed was beyond maintenance. So through an acquaintance in the marina, I got a young guy who worked for him and that had a good reputation. We discussed what I was looking for and he agreed to do it on an hourly basis. He got right on the work and with some help he removed the generator and had a plan to do what I wanted.
The generator torn down to its basic parts, sanded, baked, painted with primer and then enamel.
The core of the generator.
He took the generator to his home repair shop and began tearing it apart. He and his crew totally stripped the engine and generator down to its parts and then sanded all the rusted areas, applied a primer paint and a finish engine enamel after baking them. He replaced the bearing on the windings, rebuilt the sea water pump, replaced the injectors, acid-flushed the sea and fresh water cavities and reassembled with the new parts. It took some finesse to schedule the reinstallation. We reinstalled the generator as one of the last things we did at the yard before launching. I arranged for the yard to lift it up with their forklift and they were able to put it right into the cabin making the replacement very easy.
The generator ready to go back in the boat.The generator being lifted by the yard forklift for dropping into the cabin.
Dropping the generator into the cabin.
After reinstalling it we noted a slight leak in the raw water pump. We have had a leak in that pump since it was new. While it was still under warranty I had the pump replaced but I still seemed to have a leak that I could never find. During his work Oscar he had asked me to buy a rebuild kit for the pump, which I did, and he rebuilt the pump. After all his work it still leaked so he removed it and had a gasket fabricated that finally stopped the leak. After 10 years that original problem was solved.
The reconditioned and reinstalled generator.Once in the water with everything adjusted we started it and it ran better
than it had since it was new. I’m looking forward to putting many more hours on it in the future.His final bill was a fraction of the other estimates.
Rigging
When we bought our boat the mast and rigging was removed for shipping. At the time we inspected the rigging, replaced most of the running rigging (lines) and corrected some defects in the original configuration. That was 10 years ago. The standing rigging is now over 20 years old and spent the last 10 years in the harsh tropical environment and there were many brown stains starting to appear. So as we discussed our refit plans the rigging became a mainstay.
The new rigging unboxed.
This is the shroud connection to the mast. A simple piece that slides into a bracket. Changing them out was very simple and quick. The Forestays and Backstays were connected by clevis pins.
Rigging on a sailboat is an anomaly. It is one of the most crucial systems that you have but it is susceptible to failure at anytime. When we pulled our rig it had had over 20 years in its life. Many riggers tell you to replace a rig at 10 years but definitely by 20 years. Our first boat had a rig over 30 years and it was fine. There are many variables although people try to enforce arbitrary rules.
The mast being reinstalled.
Once we pulled the mast the rigger began talking about replacing it because of its age. I looked at it and there was a lot of surface corrosion. But, the thinking is that you don’t know what’s inside. So, as I looked at it I had to decide was it worth having my helper spend a few days polishing it to see if there were any bad areas or just replace it. I opted for the latter. I was confident that we could get more life out of the rig but it would be awhile before we could get it done at another place this good to replace it.
Lining it up

I ordered the package from Seco South and talked to others and got some recommendations. I commiserated with the yard manager about the rigger who then called someone that came recommended by 2 others and I hired him to handle the rigging and restepping the mast. In the end the cost of my new rigging including shipping and the new rigger was less than the rigging hardware package our original rigger wanted.
The mast coming through the deck as my electrician begins pulling the wires from the bottom of the mast to feed them through the hole on the side of the mast for connection to the boat electrical system.
The other part was replacing the running rigging. When we bought our boat 10 years ago I replaced most of the running rigging. Running rigging is the lines that make up halyards and sheets. The idea that it was finished was again an idea I didn’t entertain. But, realized that at some point we would need to replace that too and it would be easier now with the mast down. I contacted our old friends at Oxford Boatyard in Maryland where we outfitted the boat and gave them the measurements and we got our new lines and halyards. All the standing and running rigging fit perfectly when we installed it.
We had both our anchors regalvanized and the 30' chain for our secondary anchor that's 10 years old. We put the 33kg Rocna on the boat when we bought it and the 45# CQR was on the boar when we bought it.
All the rigging arrived timely and was a cinch to put on. The new rigger I hired charged what I expected it should be and he helped step the mast when we launched. The only hard part of adding the new rigging was changing over the furlers and even that wasn’t that difficult once the drums were disconnected. The rigger made a modest effort at tuning the rig but I checked it with my Loos gauge and it was way off. I decided to let them stretch for a few months before I tighten them down correctly.
Interior
The interior work was not initially part of the refit plan but soon became a major piece. The new Island Packet boats are equipped with Corian countertops and a nice cutting board top stainless steel stove. We decided it would be nice to have that look in our galley. At the same time the wood around our entryway and our floors were getting worn and needed refinishing. When we initially met with the Manzanillo marina folks we discussed it with them. We had already talked to the Island Packet factory about manufacturing the new counters and they agreed to do it if we could bring them a template. So before our trip to the States the carpenter from Manzanillo Marina came over and removed the cabinets and did a template of the counters.
The cabinetry removed.
The space sans cabinets
With the cabinets off we learned a lot about the construction of our boat. All of the construction is thoroughly integrated and then fiber glassed into the hull at several places to form a strong structure. We discussed the counter removal with the carpenter, and he initially didn’t see it as a problem. But, as he studied the integration before doing the final removal he realized it would be almost impossible to remove the old countertops. As a result the new countertops were laid over the old Formica which presented some interesting challenges that we eventually worked through. We would have much preferred to remove the old counters but it wasn’t practical. We’ve adjusted to it well. After the counters were installed we added a tile backsplash around the sink and the stove in an ocean blue color that sets off the Corian, the teak and the cutting board.
The cabinets arrived
Once the counters were finished they moved on to sanding and staining the wall and floor sections that needed it. It took several days of sanding and they tried to drape everything as best they could to contain the dust, but when we got back in the boat it took a lot of cleaning even beyond what they did to get the boat clean. Now she looks like a new boat inside.
The floor sanded and prepped for painting.
The staining in progress
The refinshed product
As we were working through the upgrades and knowing the labor costs here we decided to replace the cushions on our settees. We ordered fabric from Sailrite where we bought all of our canvas and fabric supplies. We also used a different fabric guy for the cushions than the one we used for the outside canvas. He took Linda to a wholesaler where they picked out the cushion foam material. Once the covering from Sailrite arrived he made the cushions. He couldn't put them in right away because the inside was torn apart for the restaining.
Our refinished settees.
Electronics
One of the original pillars of our refit plan was to upgrade the electronics. When we bought our boat 10 years ago it had no electronics so we installed an entire Garmin suite of instruments to provide us the data that we needed for offshore cruising. In electronics life, 10 years will see a lot of evolution. So we thought it was a good time to look at it. We had problems with out autopilot almost from the beginning. Garmin said it was the right size but it didn’t seem to have the power it needed to move our heavy boat in heavy weather. We actually replaced it under warranty once and had to do several other repairs to it. Over the past several years we began experiencing issues with the chart plotter so we thought it needed to be replaced.
The old electronics we replaced. The AIS, the Auto-pilot and Radar.
In addition to those two upgrades we thought we needed to correct other issues, we wanted to upgrade our radar to Doppler to give us better weather visibility and upgrade our AIS as well to the new higher band. We have also had issues in the past with intermittent AIS failures that could have been the chart plotter or the AIS device.
The old instrument panel.
The instrument panel with the new instruments.
Our contractor at Manzanillo marina recommended an electrician, Alex Varela, and we began discussions with him about replacements. We settled on replacing those 4 items with B&G/Simrad equipment. I liked the Simrad Autopilot because it had a separate hydraulic pump and system that seems more reliable than the Garmin. We upgraded the radar to 20” from 18” and it’s Doppler so it will have a more robust return.The Chart plotter is the same size as the Garmin but the display seems more robust.Finally, the upgraded AIS has a wider range and transmits on the satellite system and not just line of sight.We also needed to add a signal splitter to the VHF antenna because unlike the old AIS, the new one didn't have on built in.
The new helm.Over the past couple years we were also experiencing failures in our engine gauges that recently included the total failure of the electric fuel shutoff. So while in the States we purchased all new engine gauges, senders and switches. Alex installed these as well.
Another area of frequent concern was our bow thruster. It didn’t seem to have the energy it did originally. Alex removed it and cleaned the motor and the brushes. Reinstalled, it worked great. We are continuing to analyze the wiring to see if there is a better arrangement and may connect it to the house bank so that it will have more and longer power than what is provided by a single battery. One time coming up the Intercostal several years ago our start battery died because the line from the alternator broke off. Had I been able to use the house battery bank we would have had use of the thruster in close quarters.
Our new radar after mounting.
The electronics portion of the plan expanded while we were working on other things. The first issue was the starting battery failed. Our original starting battery lasted 7 years with one total discharge. We replaced it with a smaller battery that lasted about 4 years. Now we replaced it again with a similar battery but I’m not happy with it and will probably replace it.
We put the old chart plotter on the electronics panel as a repeater and with all the charts has our historical data and can be used for planning without lighting up the helm.
Then, while we were doing our work in the Boatyard I had our electrician check our solar panels because I have thought for some time there was an issue with them. Turns out that 2 of the 4 weren’t producing any power. 1 was partially producing and only 1 was producing close to capacity. So, out of about 27 amps of capability I was getting on a good day 7 amps. Solution was buy new panels that we installed and are back up to getting 20+ amps.
Shortly after we discovered the paucity of solar input I discovered we had a battery issue. One of our 6 house bank batteries was getting hot. I removed it from the bank and it was swollen so it was defective without even checking further. When I was disconnecting the batteries I found one on which the posts were irregular, I pulled that one out of the bank as well because I could never get the cables back on it.
Our battery compartment as I work to reconfigure the batteries to remove the bad one.
Expensive solution but I replaced all 7 batteries (6 in the house bank and the starter) with Group 31 AGM Lifeline and had them shipped from the States. The choice of batteries in Cartagena is very limited.
Exterior
When we bought the boat 10 years ago we made a number changes to the previous owner’s configuration. We removed the davits because we were adding an arch. We removed an antenna pole from the transom. We also learned that sometime in a prior life in stepping the mast the boom was dropped. The yard that did it did fiberglass repairs that weren’t quality work. There were also some chips and spider cracks forming in the gelcoat. So it was a goal of mine since we bought the boat to repair these glaring issues.
The cabin top with all the hardware removed and the gelcoat taped.
When we were in the early stages of planning our work, we had friends in Cartagena having their boat totally regelcoated. When we talked to the yard we discussed our desires and they presented us with several options. They talked us out of totally regelcoating the entire boat. We finally settled on having the cabin top regelcoated and having all the nonskid repainted. In addition, the hull sides would be refreshed with a lot of sanding and waxing to restore their luster. Sanding the hulls for the work required a new name decal which was a good idea. The old one was also beginning to chip in places.
Repairing the teak
One of the spots being repaired.
Doing the work required a lot of prep. We had to remove everything from the deck. We removed hatches, grab rails, dorades, line handling blocks and sheaves the traveler and clutches from the cabin top. Of course when they were done we had to put it all back in. We experienced many damaged bolts in the process and finding replacements was not always easy.
The finished dorade project. The new and old scoop base.
What it looked like after we removed everything
While everything was off we had all the stainless machine polished. My helper knew a place that refabricated the acrylic covers for our dorades and another place that fabricated new mounts for the scoops. The marina even reenameled the inside of the scoops.So our dorades are brand new/
With everything off it gave us a chance to rebed all of the bardware when we reinstalled it. With the boat wide open we were fortunate it didn’t rain at all during the weeks of doing this work.
Restaining the companionway
We removed all the rubrails from the sides of the boat. We have two sets of rubrails. An upper set that screws into the teak toerail and a lower set that screws into a wood extrusion. We took them all off and had them machine polished which made them almost look like new. When we took the rails off the teak toerail we found some areas that were rotten and one small area had termites.
After the hull refurbishment was done the new name decals were applied. Same as the old ones.
I hired a local guy who did a great job of cutting out the damaged portions and then installing new teak in their places. The worst spot was in the port stern corner under the cleat. After the wood was finished and before we stained it I purchased some commercial grade insecticide and we sprayed it onto the raw teak. The rest of the teak we light sanded and sprayed all that as well. We sprayed several times to allow the chemical to soak into the wood to prevent any reinfestation or to end any additional damage if we missed some. We also sprayed inside the boat since everything was open and dishes put away for all the work. Hopefully, we’ve ended the infestation and protected from getting it again.
Bottom Job
Everybody always assumes that boats float in the water without any concern about the chemical and biological reaction going on. Boat bottoms require constant work to prevent organic growth. But, even more importantly is the effort to prevent water infiltration into the fiberglass. Boat builders put gelcoat on the bottom in order to prevent the water infiltration but that wears out eventually and water will penetrate the gelcoat. We had another issue. When the boat was built there was an assumed water line that worked for the boat’s previous life. After we moved aboard and began adding heavy things like a solar arch, a generator and supplies for repairs in random places the boat floated deeper in the water and marine growth occurs on the fiberglass without the antifouling paint. Old ships used copper panels on the bottom.
Work on removing the bottom paint.
When building our boat Island Packet used an enhanced gelcoat that had an expected life in excess of 10 years. Our boat was 11 years old when we bought it so one of the first things we did was to soda blast the bottom to remove all old paint and I applied an epoxy barrier coat to the hull to prevent any water penetration. The barrier coat is good for 10 years so it was time for it to be replaced. There was also an issue with the barrier coat in Rio Dulce after only 3 years. The yard was to sand off the old bottom paint but they got overzealous and removed parts of the barrier coat as well in places. To remedy that they repainted the bare areas and then added a coat. I also paid for another coat, but there was still concern about the overall efficacy of the process so now at 10 years it was time.
Laying out the new paint lines.
The yard at Manzanillo totally removed all the paint and old barrier coat down to the original gelcoat. Thankfully, the hull was completely sound with no evidence of any water infiltration or exfiltration anywhere.
They then applied 5 generous coats of Interlux Interprotect 2000 alternating colors between gray and white so it was easier to tell coverage when painting. After the barrier coat they added 3 full coats of Petit Trinidad which is a hard paint and will require periodic cleaning.
Applying the barrier coat. Applied 5 coats alternating colors to make overcoating easier. I guess it's not common here but the yard guys were very happy. The boot stripe and the accent stripe are already on.
After we launched the boat in 2014 it was heavy in the front until we added things, and it got lower and lower in the stern. After our first 2 years we raised the waterline. The crew at Oxford Boatyard did an excellent job repainting the waterline. Our waterline includes 5 stripes. The first is the top of the bottom paint which is the key. Then we have a stripe of gelcoat. Then the boot stripe. Then another strip of gelcoat and then the Island Packet gold decal accent stripe. Figuring out a change to the water line includes all that and takes thoughtful planning to make it look correct.
The finished bottom. Except for the stands.
After we had the bottom totally sanded I worked with the marina crew and we reestablished the waterline; the size and location of the bootstripe, and the layout of the other stripes. They sprayed a new strip of gelcoat around the boat based on our layout and it served to delineate the pattern. The bottom paint would come up to the bottom of the new gelcoat, The boot stripe would be centered on the gelcoat strip and the gold accent stripe would go at the top of the new gelcoat.
It all worked very effectively and differences in the gelcoat can’t be noticed and since we’re back in the water, the water is staying on the antifouling. Objective achieved.
Basic Boat work
In addition to all the specific areas mentioned above, we did other deep maintenance types of work. Much of the above work was contracted but this my helper and I did. One major project was to paint areas of the boat that are usually inaccessible with Bilgekote, which is a heavy paint that can’t be done while living in the boat. When we emptied the lazarettes we had those painted. When the generator was removed we painted all the areas on the inside that aren’t accessible with the boat loaded. On the hard we emptied the anchor locker because I had my anchors and one chain regalvanized locally. With the locker empty we cleaned and painted it. I did it when we first bought the boat but with all the use it gets it needed it again.
One of the projects was to remove the rope clutches from the cabin top for the gelcoat work and to clean and lubricate them.
We then worked our way back through the boat in each bilge area. We removed hoses from the seacocks and lubricated them all and repainted the open areas. At the holding tank we found that the two diverter valves to direct effluent to the tank or overboard and from the tank to pumpout or macerator were immovable. Normally, I work all the through hulls regularly but since we haven’t used the holding tank in over 8 years, those valves were not moving. After removing the hoses from those valves we found the hose leading from the forward head was almost totally blocked. It wasn’t possible to remove the hose so we tried other options to clean it. Finally, we got some muriatic acid and soaked it and the hose cleaned up. At the same time we were working on the valves themselves and eventually got them cleaned up enough so they would work. In the process of working the discharge valve we broke the plastic nipple the connected the tank to the valve. At first I thought we broke the tank, but it was a plastic nipple that I was able to easily replace. Through the opening I got a view inside the tank. That project took the best part of a week before it was finally finished.
Old packing from the rudder shaft.
The rudder shaft after repacking.
Finally we got to the main bilge area. In our boat it is impossible to get to. So we removed the bilge pumps and all the hoses and wiring and poured paint into it and using a small roller on a stick we were able to spread the paint around nicely. After it dried we reinstalled all the fixtures. We needed to get this all done before the carpenters refinished the floors.
While working to clean around the holding tank the connector for the lower diverter valve broke. Turns out it was just plastic. Had a new one made. This was the port into the holding tank that we haven't used in 8 years. It was in much better condition than I thought.
We cleaned the bilge and everything in it including repainting the deepest part of the boat.
Next project was to replace the packing on the rudder and the propeller shaft. I’ve done the prop shaft packing many times but the rudder shaft was a challenge. To move the bolts took a 24” pipe wrench that we were able to borrow. The 3/8” packing I was able to buy locally. Turning the nuts off was not so much of an issue but after putting in the packing and tightening it down it took both of us to turn the wrench. After we tightened the last ring we checked to be sure we could still turn the wheel. It was much stiffer than before but not packed so tightly to interfere with operation. I’m sure that’s the first time that packing has been changed.
Changing the propeller shaft packing was fairly easy compared to the rudder shaft.
After launching neither shaft leaked.
The new stove required the installation of a new gas hose to replace the copper line with a hose. Here it is installed in the under sink cabinet.
Summary
Our original 10 year refit was a victim of scope creep. Pausing to update a few things turned into a major event that impacted at least a full year if not more. Our 10 year cruising anniversary also coincided with our 30th Wedding Anniversary and my 75th year so it became a special event.
I have appended a copy of our Workplan spreadsheet to this blog article to list every major work item we did but without it's cost.
Our life revolves around our home and it is the most important thing beyond our lives themselves. With the refits and upgrades we have done, we expect them to serve us as long as we may need them. I hope we will be back in Cartagena in 10 years to do a refit.
The result of every day in the Boatyard.
Copied from Spreadsheet
Area of work | Task | Contractor | Status | ||||
Rigging | Unstep the mast | Luigi | Completed | ||||
Rigging | Restep mast | Eugenio | Completed | ||||
Rigging | Replace outhaul/furling lines | Eugenio | Completed | ||||
Rigging | Purchase outhaul/furling lines | Oxford Boatyard | Completed | ||||
Rigging | Maintenace of main furler | Self | |||||
Rigging | New mainsail | Quantum | Completed | ||||
Rigging | Anchor regalvanizing | Daisey | Completed | ||||
Rigging | Headsail repairs | Renzon | Completed | ||||
Rigging | Examine and clean rigging | Self | Completed | ||||
Rigging | Replace sheaves | N/A | N/A | ||||
Rigging | Splice rodes to chains | Juan | Completed | ||||
Rigging | Replace shrouds and stays | Eugenio | Completed | ||||
Rigging | Purchase shrouds and stays | Seco South | Completed | ||||
Rigging | Purchase halyards | Oxford | Completed | ||||
Rigging | Install halyards | Eugenio | Completed | ||||
Rigging | Replace topping lift | Self | Completed | ||||
Rigging | Service winches | Self | In progress | ||||
Rigging | Replace winch bases on mast | Self | Completed | ||||
Rigging | Replace steaming light wire and other mast wire connectors | Alex | Completed | ||||
Hull and Deck | Strip the bottom | Manzanillo | Completed | ||||
Hull and Deck | Raise the waterline | Manzanillo | Completed | ||||
Hull and Deck | New barrier coat and bottom paint | Manzanillo | Completed | ||||
Hull and Deck | Purchase Barrier coat | Budget Marine | Completed | ||||
Hull and Deck | Purchase Bottom Paint | Defender | Completed | ||||
Hull and Deck | Hull gelcoat refurbishment | Manzanillo | Completed | ||||
Hull and Deck | Deck gelcoat | Manzanillo | Completed | ||||
Hull and Deck | Purchase gelcoat | Island Packet | Completed | ||||
Hull and Deck | Purchase yellow stripes | Island Packet | Completed | ||||
Hull and Deck | New name decal | Island Boat Lettering | Completed | ||||
Hull and Deck | Remove/replace stanchions | Self | Completed | ||||
Hull and Deck | Remove/replace rubrails | Self | Completed | ||||
Hull and Deck | Replace companionway slides | Self | Completed | ||||
Hull and Deck | Replace section of rubrail | FIS | Completed | ||||
Hull and Deck | Rebed chainplates | Self | Completed | ||||
Hull and Deck | Refinish teak | Self | Completed | ||||
Hull and Deck | Replace slides on companionway | Self | Completed | ||||
Hull and Deck | Repair damaged wood | Alberto and Elias | Completed | ||||
Hull and Deck | Polish rubrails mechanical | Felix brother | Completed | ||||
Hull and Deck | Anchor roller improvement | FIS | Completed | ||||
Hull and Deck | Fumigation | Self | Completed | ||||
Hull and Deck | New dorade covers acrylic | Local | Completed | ||||
Hull and Deck | New dorade covers base | FIS | Completed | ||||
Galley | Replace countertops | Manzanillo | Completed | ||||
Galley | Fabricate countertops | Island Packet & Shipping | Completed | ||||
Galley | Add insulation to fridge | Self | Completed | ||||
Galley | Purchase new stove | Go 2 Marine + shipping | Completed | ||||
Galley | Install new stove | Manzanillo | Completed | ||||
Galley | Replace gas line | Self | Completed | ||||
Galley | Tile backsplash | Manzanillo | Completed | ||||
Galley | Replace switch for fridge drain | Ales | Completed | ||||
Galley | Replace lift support in fridge | Self | Completed | ||||
Interiror | Screen repairs | Glebe Creek | Completed | ||||
Interiror | Restaining | Manzanillo | Completed | ||||
Interiror | Refinish floor, door and wall | Manzanillo | Completed | ||||
Interiror | Purchase stain | Defender | Completed | ||||
Interiror | Paint bilge | Self | Completed | ||||
Interiror | Paint other areas | Self | Completed | ||||
Interiror | Repair peekaboo shades | Self | N/A | ||||
Interiror | Replace cushions | Pedro | Completed | ||||
Interiror | Repair nav station seat | Carlos | Completed | ||||
Interiror | Service all hull and diverter valves | Self | Completed | ||||
Interior | Clean mattress covers | El Ensamble | Completed | ||||
Interior | New mattress | Pedro | Completed | ||||
Canvas | Replace dodger/bimini | Renzon | Completed | ||||
Canvas | Replace surround | Renzon | Completed | ||||
Canvas | Replace sun cover | Renzon | Completed | ||||
Canvas | Replace hatch covers | Pedro | Completed | ||||
Canvas | Purchase Canvas supplies | Sailrite | Completed | ||||
Electronics | Replace chartplotter | Alex | Completed | ||||
Electronics | Replace radar | Alex | Completed | ||||
Electronics | Replace auto helm | Alex | Completed | ||||
Electronics | Replace engine instruments | Alex | Completed | ||||
Electronics | Replace AIS | Alex | Completed | ||||
Electronics | Replace Smart plug | Self | Completed | ||||
Electronics | Purchase Smartplug | West Marine | Completed | ||||
Electronics | Replace battery charger | Defender | Completed | ||||
Electronics | Install battery charger | Nester | Completed | ||||
Electronics | Service bow thruster | Alex | Completed | ||||
Electronics | Purchase new battery charger | C 6 Marine | Completed | ||||
Electronics | Purchase electronics | Oxford Boatyard | Completed | ||||
Electronics | Install new arch solar panels | Alex | Completed | ||||
Electronics | Install new starter battery | Self | Completed | ||||
Electronics | Purchase new starter batter | Self | Completed | ||||
Electronics | Buy new solar panels | Self | Completed | ||||
Mechancical | Remove/recon genset | Oscar | Completed | ||||
Mechancical | Engine cooling system flush | Self | Completed | ||||
Mechancical | Remove and flush heat exchanger | Self | Completed | ||||
Mechancical | Remove core of HE and Oil Cooler | Local | Completed | ||||
Mechancical | Recondition turbo | Servi Inyeccion | Completed | ||||
Mechancical | Clean exhaust | Self | Completed | ||||
Mechancical | New drive shaft packing | Self | Completed | ||||
Mechancical | New rudder packing | Self | Completed | ||||
Mechancical | Install new engine panel | Alex | Completed | ||||
Mechancical | Replace bilge pump hoses | Self | Completed | ||||
Mechancical | New brushes for bow thruster and cleaning | Alex | Completed | ||||
Mechancical | Rebuild engine injectors | Servi Injecion | Completed | ||||
Mechancical | Rebuild genset injectors | Servi Injection | Completed | ||||
Mechancical | Parts order from Yanmar | Bay Shore Marine | Completed | ||||
Mechancical | Parts order for Northern Lights | Bay Shore Marine | Completed | ||||
Mechancical | Change oil in bow thruster | Self | Completed | ||||
Survey | Perrito | ||||||
Labor | Felix | ||||||
Storage room 7/5/24 - 3/21/25 | Manzanillo | ||||||
Land storage 1/8 - 3/21 incl mast storage | Manzanillo | ||||||
Utilities on shore | Manzanillo | ||||||
Additional shipping | |||||||
Apartment 1/5 =3/31 |