Came to JWS late 2012, with Osmosis in the hull from the offset we know this wasn’t going to be a straight forward treatment. First hurdle was making the decision whether to machine or hand peel her, in the end a combination of the two was carried out. We generally tent up the hull mainly to protect the blasted hull, before proceeding to the hot-vac treatment, however with this project we tented her then left her with inferred heaters on localized seeping areas while tented for 7 week in total to try and draw the moisture from her hull. While in the care of JWS the owner opted for some other items of work to be undertaken, such as the application of Copper Coat, new headlining in the saloon, and varnishing of the floor boards new treadmaster paint applied to the deck and also the replacement of all seacocks with TruDesign The following images show the Osmosis treatment. 1-3 – Hull before work has started 4-7 Hull peeled 8-9 Blasted 10-12 Inferred on seeping areas 13-15 Hot-vac treatment 16-18 Application of the extra layers 19-23 Osmosis Epoxy coatings 24-26 Copper Coat applied
There was water seeping throughthe hull from the keel bolts. To repair this we grinded back the area on both Port and Starboard side to allow the water to be released. 2 infered heaters where put on both areas and allowed to dry over 1 week. The area was then cleaned and prepped for re-lamination back to the orginal thickness.
Once this was completed we moved on the applying the stifferning layers in varioes areas of hull using 450csm and 600csm.
Next step was to bring her into the shed for the hot vac treatment, in most cases we would only have to carryout 1 course of Hot-vac treament in this instance due to the high moisture content trapped in the hull we had to carryout 2 rounds of the hot-vac treatment.
It was agreed to add an additional later of matting to to the hull, this was done using 3 layers of 450 CSm and 2 layers of 600csm.
Now that the layers have curred we carried on with the application of AMC-100 Epoxy coatings. We applied 1 layer, the hull was then fill and faired off before appliying the further 4 coats.
The treatment was completed and we finished with an application of Copper Coat.
Please click on the link to see the other work carried our during her stay –
This boat came to during 2016 for the re-spray of the hull, as we were unsure on the paint system that had been used previous we had to carry out some test to guarantee the new paint system (AwlCraft) will be compatible with the old.
After this was carried out it was apparent that extensive sanding was required to remove the original paint system, Generally we allow 12hrs of prep sanding so the hull is clean and ready for the epoxy Primer, with this project a total of 48.5hrs were required. Due to the extensive sanding we then had to apply a specialist hi-build primer followed by 5 layers of Hi-build before moving on to the 545 epoxy primer. Once the hi-build layers were complete, we then made a start with the 545 Epoxy primer coats, 5 in total were sprayed on with filling fairing of the hull. After Primer coats applied we sanded down the hull and gave her a wash down ready for the top coat application.
In this project the colour we used was Awlgrip 2000 Topcoat Orange RAL 2004, we applied 4 layers before sanding the hull back and applying another 4 layers of topcoat.
This little motor boat came to us back in 2016 for a Hull Respray, her original colour was green, the owner wanted a Royal Blue hull. During her stay here she grew to become a full refurbishment of hull, superstructure and cockpit area.
Work started with a hull blast to remove all anti-foul from the hull. All old epoxy was sanded off of the hull and new epoxy applied along with 5 new coats of Gel Shield 200 primer and anti-foul as required. The original colour of the hull was green but the owner wanted this changed, he opted for a flag Blue shade of the AwlCraft 2000 range for the hull, during this time the owner opted to have the Super structure re-sprayed also, in Super white again from the AwlCraft 2000 range.
As you can see from the pictures the end result was fabulous, please view the video of the application being carried out.
In addition to the spray work JWS was asked to refit the interior of the boat with all new windows and internal soft furnishings, carpets, new bulkhead coverings, all new electrics and some deck hardware. We worked closely with the owner to achieve his exact requirements resulting in a smart and elegant representation of a SeaRay 24.
Here is a 35ft Laurent Giles wooden Classic, came to us late 2013, after a complete hull survey it was apparent that this was going to be a big project, after a sit down chat with the owner we decided to break the project down into sections.
First section of work was to remove all the paint from the hull, this was carried out by blasting with soda, the soda media is quicker at removing the paint and is kinder on the planks than burning it off, plus burning off just eats up man hours.
Next display of pictures are some internal shots of the problems that boats had for example, all the metal work was rotten and a lot of the floor straps had no fixings through into the wood keel and also wood frames that hold the planking together were found to be cracked and shifting.
The next section of work was the removal of the mild steel floor straps and floors, all were removed, filled and faired so that we could use them as patterns for the new castings. All straps were replaced with AB2 bronze fittings as per the owner specification so that the boat would not have any more rust problems in the future, secondary to this they are incredible strong and with last for 30+ years. All new floor, floor straps and brackets were individually drilled and all new bolts were made and threaded by hand as we were unable source the required length off the shelf.
We removed the planking from the Port and Starboard side to expose all the work ahead, nearly all grown wood frames (3” x 21/2”) and the small wood frames (11/4” x 11/4”) at the turn of the bilge were fractured on both Port and Starboard side. You can see from the pictures below the amount of work that has gone into re-doing all the frames, the total that required replacing was 156 small wood frames and 12 large grown wood frames all had to be hand cut and all the wood had to be individually cut into laminates and all glued in jigs to form the shapes required for all frames and then all had to be fitted with copper nails and roves.
The following photos show where the chain plates were fixed to the hull, the frames were rotten and in all 10 small wood frames 4 of had to be completely replaced and 6 grown frames needed replacing, all had to be re-nailed using copper nails and had new strap frames and bronze chain plates.
Plank work to the hull was our next section of work, the removal and replacement of 6 Port and 7 Starboard planks, this was carried out using 10m x 800mm planks of Kayenta mahogany from the Cashew tree, the individual planks were removed and a template was taken for the new planks, this was transferred to the plank of mahogany and cut to size and all shaped by hand using planers etc. 2 planks per length, on planks where we were required to do one plank, the planks were joined using stopped scarfs, this process was carried out individually 26 times and all had to be copper nails and roved in place by hand.
We had some work to do to on the coach house roof due to it having some rotting sections and leaking. We removed the entire coach house roof from the boat so that it was easier to work on while we removed all the varnish, this also gave better access to the deck area and the works required.
With the refit of the mast ring on the forward section, this was found to be rotten and on dismantle it was found to have peg board instead of plywood under the old teak boards, we removed this and re-worked the area to make it watertight and looking good again.
Removing the top was not easy as all fixings were bronze bolts that were specially fabricated for that purpose, therefore we had to have new ones fabricated to the same spec as the old. With wooden boats all the old fixings they used where hand made to the spec required, over time we at JWS have managed to enlist some specialist fabricators that can assist with projects like this, without them carrying out re-fits of this nature would be extremely difficult.
The next area we tackled was the deck, we removed the old deck and re-fitted a new 12mm marine plywood sub deck with hardwood lower margins and then fitted a new teak deck, teak margins and 48mm 5 x 5mm rebate, as with all boats when we removed the old deck it exposed more rotten wood deck beams and the top plank to the hull had to be totally replaced with new.
The following pictures show the work to the new chain plates and new chain plate straps and also the bar strapers that all had to be hand made out of silicon bronze bar and all new wood block and the fitting of all.
Here is the type of prep work and pre-fitting of plywood panels, all are painted before fitting, this quickens up the finishing time. With access to difficult areas all deck beams are painted and all bulkheads are pre-varnished before fitting, all works carried out is by hand and all are checked before final fitting.
Below you can see all marine ply wood is cut to shape using templates, then taken to the boat and cut to fit, then all is temporary fitted and all deck beams are drawn on and all plywood is taped up and then painted to a gloss finish ready to be fitted to the boat. All are fitted with 316 stainless steel wood screws, all are filled and sanded flush. The hard wood margins are made to fit and glued in place. The whole area is cleaned up ready for new teak deck.
Teak decks with curves like this require large planks of teak, the widest plank we used on this project was 12mm thick 400mm x 3000mm long, this ment we could get a long run on a curve, you can see there were a lot of wide boards required, these were all marked up and all cut by hand along with all rebates being cut with a router. All work was pre-templated before cutting to minimise wastage and so we don’t have any pre-problems with lines. All the glue used in the section are epoxy based glues.
On removal of the aft deck area we found that all deck beams and the transom face was completely rotten and delaminating so we removed all the structure and as you can see from the pictures below it was completely re-built from scratch and all new laminated beams and frames, all were primed and re-dambolined out.
All the teak margins were individually templated and cut from teak boards and finished first then the teak decking individually laid one at a time, due to the clamping and gluing the planks in place.
The following pictures are of the teak deck being laid, deck caulking applied with any excess being removed.
You can see the new coat roof going on, all was finished off with 5 coats of Varnish.
Final stretch of the main project was her hull and interior (The pretty parts)
As you can after the hull was blasted we sanded her back and washed her down to removed any contaminants.
We then applied coats of primer, she was then sprayed with AwlCraft 2000 paint system.
We had new decal/name made to the owners specification and we applied this to the transom, the font used here is Lucida Callgraphy
At the start of the job the most of the interior was removed, this enable the owner to have more control over the new layout of the galley and cabin areas.
Once the lay out was achieved all was coated on primer and damboline paint and all wood work received 5 coats of Varnish.
There a few pics of some of the deck hardware we purchased also.
It was then time for her to leave our shed, we launch her in the water where she awaited her new mast to be fitted.
When it comes to a new mast we have a great company that will fabricated to any spec we provide.
Once we have the new bare mast back in the work shop it is placed on trestles ready for dry fitting of parts and varnishing. all cables are run through the mast.
The old track is dry fitted and any alteration required are made at this point.
The mast head fitting and spreader fixing are fitted.
Then all parts are removed in preparation for the application of varnish, a light sand is carried out before proceeding with the varnishing coats
Once complete we had 1 Degree West Ltd fir the standing rigging and we assisted them in fitting the mast to the boat.
Since leaving us Farida restoration has been published in a number of boating magazines, please click on the links below to take a look –
Came to JWS in 2019, Following some moisture readings it was found to have Osmosis and was in need of a full treatment. treatment, The owner accepted and we prepped her for the first job was to Gel peel the hull using a peeler. We then blasted hull to open up the hull fibers and freeing the contaminates from the matting, this aids in the drying process.
At this point we removed all below the water line through hulls, unfortunately in this project none of the ball valves were serviceable so we supplied all new parts for 5 through hulls. The new thru hulls were fitted and the ares cleaned.
We also removed the rudder, to access behind and cleaned ready for the same application as the hull.
After blasting she is hot washed 10 times over 14 days to aid in the drying process. Once dry she was moved into the workshop ready for the hot-vac treatment. In most Osmosis treatments only 1 course of hotvac is required, however due to the high level of moisture being retained in the hull, an additional 3 courses of hot vac were needed. After hot vac treatment the whole hull was sanded and then 1 coat of Jotuns Epoxy megacote is applied. The hull is filled and faired, then the following 5 coats of Megacote is applied.
Due to the severity of the osmosis and the amount of materials removed during peeling etc we applied an additional layer of 292 tapered cloth, this was applied using Ampreg 30 resin and peel ply cloth before the Epoxy Megacote was applied.
After the additional layer was applied and the Osmosis prevention epoxy applied and cured. The boat is lifted so that the hull patches (Left from cradle) are sanded. Finally the keel was coated with 5 coats of Epoxy. It was time for some anti-foul, the owner opted for a Copper Coat application, please see this application below.
This was just one section of the project carried out on the Grand Banks 2018/19, was to hand varnish the transom.
The first job was to tape and prep the transom for removal of old varnish, and to protect against the varnish chemical remover. Next we removed all the fitting from the transom to access the working area, these fittings were; 2 stainless steel corner straps, 1 boarding ladder, 1 nav-light and a bathing platform, all were refitted on completion of varnish. The old varnish was stripped using a chemical remover, the whole areas was sanded and prepped ready for the application of varnish. We applied 18 coats of varnish, sanding in between each coat. Varnished used in this application was Epifanes clear varnish along with Epifanes PU, anti UV varnish, with an added drying agent mixed into the single pack.
A Returning Customer, the Grand banks 46 was re-sprayed late 2018. First we taped and prepped the hull for sanding and erect/adjust staging as required. All planks and plank seams were sanded. A wood primer was applied to all required areas, 4 coats in total, sanding between each coat. All areas that were primed were then sanded, de-dusted and prepped for the hull’s pre-coat, 4 coats of Internationals PreKote were then applied Next was to tent up the Super structure to protect from over spray, the a re-sand of the area ready for Top-coat. The working area was then sprayed with 4 coats of Awlcraft 2000 Topcoat, colour used in this application was Snow White.
A final light sand around all areas worked, the whole area then buffed to finish off.
We have also carried out this other work on the Grand Banks please click on the links below to take a look –
Hull respray on a twister 28 carried out in 2010/2011 The hull was given a complete sand, then taped and prepped for spraying by tenting the boat. 4 layers of Awlgrip 545 primer was applied then the hull sanded. We then applied 6 coats of Awcraft 2000 topcoat, in this application cream was used. The hull was then re-taped to carryout the application of the hull lines, the same application process carried out as above, this was done using Awlcraft 2000 Flag blue. All the tape removed and a buff to finish.
Another job done on the twister while she was with us in 2010/2011 – New teak toe rail The guardrails was removed along with the push and pul-pit and all was refitted on completion of work The old toe rail was removed along with both the sheet tracks. We supplied a new teak toe rail like for like, upon delivery this was cut to size, glue applied and fitted to the boat. The whole thing was then sanded and the working area cleaned.
Check out the other work we have carried out on her –
