Having replaced the broken forward transom (bow) of my Mirror dinghy, I now had to deal with the peeling paint, rotten wood and delaminated plywood below the Plimsoll line. I wasn’t looking forward to it. Inching the boat off the trailer was fun – involving two large trailer straps with hooks and ratchets, an empty oil barrel and a conveniently-placed ring on the side of a concrete shed. I could have asked for help but I’m a bit impatient. (Which is what led to all the damage to the bow and the hull in the first place!)
Boat lowered onto the grass and turned over onto planks, I could survey the hull. The sensible long-term solution was to replace the damaged plywood but (as it isn’t part of the hull per se but rather supports running parallel to the keel which seemed principally to bear the load of resting on the trailer, and as I really wanted to get the boat out while there was still some good weather) I decided to remove what I had to and epoxy the rest.
And so it began. Removing the peeling paint was easy enough. It just peeled off. Unfortunately the same was true for much of the first two layers of plywood. Faced with not enough support if I kept removing layers, I decided to only take off what was rotten and stick the rest down. That, at least, was the plan.
Paying attention to what lay beneath the paintwork, I discovered some other areas of the hull (along the keel and mostly on either side of the centreboard slot) that needed attention.
Rotten wood had to be scraped out with a wire brush, and flaking paint and epoxy removed between the keel and its metal strip protector.
Fortunately this repair coincided with a fortnight of fabulous weather, so I could be confident that the exposed wood really dried out. That, however, was the limit of my confidence. If I did all this and the boat didn’t float, Plan B was to sell it, with full disclosure. To cheer myself up, after replacing the bow, I’d decided to put a fresh coat of Bondi Blue topcoat on the topsides and finally affix the name of the boat: Harmony. Henceforth ‘it’ would be known as ‘she’.
Below the waterline, the forward hull wood and paintwork was undamaged but looked more cheerful with another coat and gave me something to do while other places were drying out.
That done and dried, I started sanding the mid and aft hull, especially where the wood was newly exposed.
Finally satisfied that the surfaces were ready, I prepared to apply the marine epoxy and glasscloth as I’d done for the forward transom and gunwales.
This stuff I’d bought from Trident UK and (unlike the Galeforce 1:1 ratio) it needed 1:5 hardener to epoxy so this time I did use the calibrated syringes. I also donned my protective goggles and pulled my neck warmer up over my nose.
I won’t bore you with all the details of the various applications of fibreglass cloth and epoxy but I soon realised that I’d need to get more if I wanted the plywood surface more even.
A mate sold me some polyester resin (with hardener) to save me the trip to the chandler’s – and I soon discovered that everything they say about the fumes from this stuff being noxious is true! And much more than epoxy. Even outside, with a breeze blowing and looking like a Martian, it was making my head spin. So the advice to use a particle mask or respirator – even when just sanding the stuff down – is sound.
As before, the sticky strands of glasscloth drove me crazy when I was trying to get the cloth to stay in place.
You really need to pay attention to the amount of hardener (1-2% only!) and mix mix mix before you apply it – otherwise, as I found out, the 20-30 minute application window shrinks to 5-10! So it was all very tedious but eventually the hull stopped looking like the surface of the moon as layer after layer of cloth and resin approximated the levels of the surface of the hull planks and protective plywood.
It didn’t help that one fine day I was sanding down the surfaces (which I did between each application) and managed to get some hardened resin dust in my eye. That served me right for thinking I could get away with not wearing goggles and put me out of the game for a few days with a painful swollen eye – which I had to bathe every few hours.
Robert M. Pirsig, the “engineer’s philosopher” who wrote Zen and the Art of Motorcycle Maintenance, warns against trying to fix a machine when you’re in a bad mood (cos all you’ll do is damage). A wooden boat, nowadays, maybe doesn’t strike most people as mechanical but it floats because of the physics of opposing forces and I think that’s sound advice. So, even though the sun shone, I resisted the urge to just get it done and instead did some jobs around the house I’d been putting off.
Recovered and refreshed, I did one last lot of sanding down the globs of resin that spattered the hull – despite my best efforts – then wiped down the whole upturned boat with a wet cloth, then a dry one, then wiped the resin with white spirit (to ‘take the bloom off’) dried that and started to paint.
The undercoat covered a multitude of sins, I knew, and I really should have applied another coat, and maybe primer (though I wasn’t sure of the order) but there was either a previous layer of paint or of resin underneath and with midsummer approaching I really wanted this boat on the water. So the Rustic Red went on (and ran over the Bondi Blue in places and had to be sanded off).
Not the prettiest paintjob but Harmony, after weeks out of the water, was finally ready for the big moment: would she float?
And, with the help of a good strong mate, I soon found out. YES!