Rebuilding the small boat

IMG_1397It’s a huge job restoring this old crashed small boat, several broken parts in the fiberglass and many holes! The boat was smashed on a rough stone beach in a strong storm, then forgotten for fifteen years in the reed…

Now the sanding and new construction (to add safety and comfort) has begun! With much fiberglass work to come…


Arrival of a small boat!

IMG_1375Today a good friend and me drove to pick up the small boat, this was a journey not to forget! Long time forgot in a forrest of reed, the boat has been sleeping in fifteens years!? We took it down, just to drag it over a heavy stone beach and then climbing a very steep hill together with the fiberglass boat… this took more than four hours of heavy and exhausting work with lifting, pulling, pushing and maneuvering the manual chain lever block.

What a day!

Now the small boat is resting in it’s new home, in my workshop…



Boat trailer…

IMG_1372A small boat in fiberglass has been given to me! The small boat isn’t ready for floating yet, but will once it’s landing in my workshop. To be ready for the transportation I searched the internet for used trailers, but with no results! However a brand new trailer cost almost the same as a brand new trailer in Denmark?!? So today I picked my new boat trailer up by the dealer and drove it back home, ready for transportation…



Roller furler system…

Wagners Shipman 28 was up for installation of a brand new roller furler from Selden, this installation was made to replace the old and tired roller furler from Plastimo. The plan was to trash the old system, but I took it back home to my workshop, maybe to fix it up and save the ridiculous many money a new roller furler system cost!

Big thanks to Wagner!

(Plastimo 809-S)



Rigging Shipmans!

DSCF1178Last time in Kalvehave harbor the two Shipman sailboats was splashed, now it was time for the rigging! The wind was as little to nothing and perfect for rigging, but the rain was keeping us all wet, until both boats rested in their finger piers again! Lars and Wagner had their longtime friend, Kim, helping them. The trio became a mixture of great stories and rigging! Excellent day!



Newborn Seaman…

IMG_1220Today the crew got larger! The newborn seaman (I think it may rank a little lower than the ordinary seaman!?) is a beautiful baby girl. We are VERY happy! Her name will be Alma and together with her older brother and sister, the crew on the sailboat are now full…

Happy birthday Alma!


Man vs. Machine!

IMG_11990 – 1 !!!

Crawling in the small lazarette below the transom, working with the grinder and power file, was and are an ongoing battle between man and machine! For now, the machine won and I’ve been out for a couple of weeks due to my injury – the world famous Tennis Elbow!

If not in the boat, below the deck – I’m continuing the everlasting research in thoughts and solutions for the DIY project. However, this is also a pleasent break from the un-pleasent epoxy and fiberglass dust…


Splashing Shipmans

DSCF1171While the Shipman 28 is resting on the hard in my driveway I’m driving around the southern Zealand in Denmark to the many harbors nearby, just to feel the atmosphere and sense how the social life works in those harbors I’m guesting. This is of course to find the perfect harbor and future home of the sailboat! While visiting the Kalvehave harbor I discovered a pair of sailboats looking just like the one in my driveway! Standing next to each other on the hard, two Shipman 28 was waiting to splash in the next couple of days. Back home again I wrote letters to put on the propeller shafts, simply to get in touch with the owners of the two sailboats.

Buying my own sailboat on the hard didn’t offer me any chance learning how to rig the Shipman 28. Now could be my chance to learn…

While putting the letter on next day, Lars, the owner of one of the Shipman 28 stopped me right next to the hull. We had a great ‘small’ talk about the harbor, the sailboat etc. and I was more that welcome to visit them and learn about the sailboats. Same evening Wagner (the other owner) wrote me, hoping to see me very soon in the harbor when splashing both sailboats.

It was a great afternoon in the harbor, the weather wasn’t, but both captains was in excellent mood. The sailboats were flying high and was set gently in the harbor basin with the mobile crane, in fact it was the same truck/crane that drove my sailboat home when I bought her and later moved the same sailboat from the front yard to my driveway due to the heavy winds of the storm Freya. I shoot some video of the sailboats coming of the hard, ending up with both of them floating next to each other again by the finger pier. The afternoon became late as we set in the cockpit of Lars’ Shipman telling stories from the past. Big thanks to the open minded captains, Wagner and Lars!



IMG_1172Below the transom and the stern platform with rising temperature, grinding and sanding the old epoxy paint and fiberglass hull, in the very small compartment – must be the sailors Purgatory on the hard!?

Is this necessary? No! Why do it?

I imagine to keep the cost as low as possible when building the sailboat back in 1971, the look and appearance below deck wasn’t important due to the extra expenses. The hull below the stern platform was rough but painted and the fiberglass material gave the surface an uneven appearance from not being sanded down properly from the shipyard. My goal is to minimize the forward and future maintenance on the sailboat, this also means cleaning and washing down! The rough surface on the hull below deck did hold up a great deal of dirt and water, but by grinding and sanding the surface into a smooth appearance the cleaning will come easy and the water will also run with ease to the bilge below!


Router vs. rudder quadrant!

IMG_1159The plate from high density polyester resin and multiple layers of fiberglass, are cut in shape with the handheld router from Bosch. The router bits with tungsten carbide tips did the job perfect…!

On the picture you can also see the model, constructed to find the right diameter of the rudder quadrant and the axis in the pedestal. The quadrant/rudder will have 80 degrees travel and 540 degrees rotation on the wheel steering (same as the Bavaria 36) so when the rudder is amidships, it can turn 270 degrees port- or starboard to reach the stop (3/4 of a full rotation)


Layout for the rudder quadrant…

IMG_1153The ‘bricks’ made from 30 layers of fiberglass was cut into a 220×220 milimeter square and sanded down to a thickness of 25 milimeters. The layout for the rudder quadrant are drawed with a permanent marker, ready for the router…


24 layers and counting…

IMG_1152To be sure the rudder quadrant will be solid the layers of fiberglass are 24 with more to come! Six sheets of fiberglass are moulded with polyester resin in every step, hardened and washed down with acetone etc.


Rudder axis ready…

In order to install the (future) rudder quadrant the rudder axis needs to be exposed! With the power file the fiberglass are sanded down in a 10 centimeter section in top of the rudder axis – just below the deck. To protect the axis it is safely hidden in a heavy tube of steel, this was cut away with the grinder in the same 10 centimeter section. The rudder axis are now fully exposed and ready for installation of the homemade rudder quadrant…


Rudder quadrant !?

IMG_1141I’ve search out the internet for solutions for an rudder quadrant! I’ve made technical drawings, asked clever people with skills in metal work and it all comes out to very expensive cost!? The rudder axis only have a diameter of 25 millimeters, this needs special work…! To keep the cost low I’ve begun to produce the rudder quadrant myself from polyester resin and endless layers of fiberglass…

(I’m making two, one as spare part…)


Next step to the wheel steering!

IMG_1142The steps for the wire bloks for the wheel steering are made and installed. Like the first step, they are made from mahogany and pre-drilled to mount the pad eyes. Look closely and you’ll see the mahogany steps are not the same height, this is made to let the two wires cross over eight other underneath the cockpit.

(Installed with thickened polyester resin)


Cut away…!

IMG_1134The wire system for the wheel steering system was chanced for better and this needed more space the the wires to run by. In order to let the wires run underneath the aft cockpit, behind the pedestal weld (?) a new cut was necessary! With a wide selection of power tools I made great acces for the wires and builded a small box to install with thickened polyester resin and fiberglass…


Construction in progress…

IMG_1128The construction of plywood are in progress, the port plate are installed with thickened polyester resin and secured with stops of fiberglass. I had some left over and used the thickened polyester resin to fill in were the plywood was uneven or smooth. When sanded the plywood surface will look great…


Mainsheet traveller gone!?

IMG_1130Where did it go? The mainsheet traveller are removed and left the cockpit larger! I’ve been searching, reading and consulting, from this the mainsheet traveller are removed from the sailboat, not to come back – instead a mainsheet bridle system are installed in the future, this allow a more open cockpit and a simple system thats easy to maintain and repair on the sea…


Chicks aboard!

IMG_1125In shelter for the rain, the chicks are resting beneath the sailboat and granting you all a great weekend…



(Light Sussex)