On the hard at Dockland 5 Marina, Whangarei
Wind: W F3 gentle breeze
Weather: sunny periods, showers, mild

We continue to make good progress on Sylph’s, what I am hoping to be, minor refit.

Yesterday after having Sylph set up in her stands, I got stuck in and attacked the first job for the refit, cutting out some wasted metal in a very localised spot on the port side adjacent the galley. This bit of corrosion was caused by a piece of timber pressed against the hull which helped support some of the interior fit out and would have been there since Sylph was originally built sixty-six years ago. Unfortunately timber and steel is not a good combination and it is not surprising corrosion has developed behind the timber strut. It probably lasted as long as it did because the spot is high up on the hull and would have been pretty dry for the most part.

While inspecting the hull below the waterline I found a problem I was not expecting. I noticed some beads of rusty water seeping out of the anti-fouling paint close to the stem line. Initially I thought it might have just been a failure in the epoxy primer but then I noticed the same problem on the opposite side of the hull and became highly suspicious that the problem was more significant than just some failed paint. I attacked both blemishes with the angle grinder and sure enough small holes in the hull were revealed. Bother! I had attended to this area extensively back in 2020 so am disappointed to discover this bit of corrosion. Hopefully it won’t prove to be anything too substantial. I have cut the worst of the wasted metal out but I still need to pull the floorboards up to have a look at the hull from the inside before I do any more cutting.

Today I have been focused on the foredeck. Some years ago, back in December 2018, I did some repairs to the foredeck using some aluminium plate I had left over from rebuilding the cockpit. Since then a number of small holes have appeared along the toe rail which I had repaired temporarily with epoxy and fibreglass. Making a more permanent repair is part of this refit’s work schedule.

To this end, first I unbolted the anchor windlass (which is also in need of an overhaul), then I unbolted and lifted the aluminium deck plate ( a few recalcitrant bolts requiring some persuasion with an impact driver made this a lengthy job), and finally I then started cutting out the rusty metal. More work required.

This evening, I made contact with a welder who has been recommended by a couple of people here in the yard, and I will be meeting with him tomorrow morning to discuss the work that needs doing on Sylph. I have seen some of Lee's work and it looks excellent, and from my initial meeting he seems very pleasant, so I hope he will be able to fit Sylph into his schedule.  Previously I have done the welding myself but, as mentioned in an earlier post, the world is becoming increasingly regulated, and Dockland 5 is no exception. They now require a hot work certificate and a ‘spotter’ to act as a fire sentry; which is all fair enough but it adds to the complexity of organising these sorts of jobs, and, of course, it costs significantly more than if I did it by myself. On the plus side I am sure the finished job will be to a much higher standard than my own welding.

Anyway, these are all minor hurdles and to be expected when undertaking a refit on an old steel boat. There are two other steel boats in the yard, much younger than Sylph, which have much bigger problems than we do (tempting fate here). One has had most of her bilge cut out and replaced so I am not feeling too overwhelmed at this stage. (Not that I gain any pleasure in seeing other people’s problems, but they can help one maintain perspective on one’s own little problems.)

All is well.

The hole adjacent to the galley (it's getting dark): 

The unplanned hole near the stem:

The foredeck being dismantled: