Merciless restoration progressing on Flying Fish

Restoration is very much about showing mercy to a beautiful old wooden boat - ironically this means mercilessly taking care of every single detail - scraping off all the old paint, replacing broken fastenings, removing, repairing and refitting ancient planks. Because of this, a restoration is always much more involved than a new build.
Flying Fish has been fitted with some splines and new planking to seal up the hull. Broken timbers (which I discovered were made of Elm) have been replaced by new oak ones. The whole interior and exterior has been scraped.

Fitting a new second plank

All down to bare wood

Spline fitted to seal large gaps

Brand new mahogany plank

Interior beautifully cleaned

Ready to refit gardboard on starboard side

New Project for the winter months ahead

Flying Fish, a beautiful classic one off, was built for a Mr W. D. Kilroy to his own design by Primmer & Snook, of Hampshire in 1936. She will be restored from the bottom up in our workshop over the next few months. As you can see from the photographs, quite a lot of preparation has already taken place. 

Scraped to bare wood!

Laying out bitumous felt on ballast keel

In mid air - preparing keel for ballast seal

The ballast keel being resealed up to the wooden keel

Happy Return at Glandore Classic Regatta 2015

During the final preparations in June it seemed almost an impossible dream to bring Happy Return to the 2015 Glandore Classic Regatta - but, it finally came true - she raced in Glandore from the 18th to the 24th of July, winning "Boat of the Regatta" as well as coming first in her class.
As with every boat, we're getting to know her better with each sail, gaining more and more trust in her seaworthiness and reaction to the slightest adjustments.

The moment of truth....

Because craning in had to fit in with so many other schedules, it happened all of a sudden on Monday afternoon in the pouring rain. Official launching will be on the 18th of July at the Glandore Classic Regatta.

That gives Happy Return enough time to swell up and get back into shape. Summer adventure here we come!

Last minute preparations at Roaringwater pier

The moment of truth - about to touch the water after decades on dry land ( sometimes not so dry).

The difficulties of bringing a boat to water....

During the many years of restoring Happy Return, we never thought much about finally bringing her to the water once she was ready. So, there were a lot of last minute logistics to sort out: new wheels on the trailer, a help from neighbour Connie O'Sullivan with his tractor on Sunday morning, organizing the crane at Roaringwater pier with the Whooley brothers.
Impossible to plan in detail!

Gleaming in the sunshine - ready to go to sea!

At the pier at last - loading fenders, mattresses, sails and camping cookers

Happy Return finally hatching!

Sometimes it seemed like this day would never come - finally Happy Return is on her trailer, almost ready to head towards the sea. Some minor details still have to be taken care of, such as positioning of the travellers, cutting the sheets and halyards, fixing the hatch hinges...and of course the name on the transom! But still, the sense of achievement is elating!

Happy Return almost ready for launching!

Unrelenting attention to detail!

A boat like Happy Return (26ft Stella One Design), is like a miniature house with engine, electrics and plumbing. Because of the limited space, every single item has to be placed very carefully, keeping in mind everything that is going to happen on board.
There are many books and articles which attempt to teach and help with boat electrics/plumbing/rigging - but ultimately, one has to really imagine oneself sailing the boat to make those crucial decisions...

Shroud plates finally fitted

Laying cables for windlass

Wiring up switches

Very nearly ready to paint!

Nosing through the door towards the sea!

One step at a time - finishing touches on Happy Return

With our self-imposed deadline creeping ever closer, the amount of details and small but important jobs to be done on Happy Return seem to be increasing rather than decreasing...

The coachroof was laid out in Samba onto the deckbeams, and then finished with fibreglass and white flowcoat.

Sliding hatch in mahogany. Traditional dovetail construction.

The anchor winch was taken apart and serviced completely before fitting to Happy Return's new swept deck.

Restoring Happy Return's Rudder

The old rudder fittings on Happy Return had completely corroded away, leaving quite a bit of rust damage in the rudder itself. New fittings will have to be made...
Purpleheart pieces were scarfed into the rudder where necessary:

Dry weather ideal for annual maintenance

One has to take advantage of this dry West Cork weather at the moment to do that necessary annual varnishing and maintenance of the wooden boats in our care.
With a few days of special care per year these boats will still be sailing off the west cork coast when we are long gone... hope fully they'll remember us - the mad boatbuilders of West Cork!

We have managed to fit three of the Ettes ( all built by us) into our workshop, as well as their spars.
To create optimal curing conditions for the varnish, we heat with two ceramic infrared heaters.

Creating optimal varnishing conditions can be challenging - so we pack as many boats into the shed as possible to take full advantage of it.

Varnishing spars. The mast to the right is that of Happy Return ( our Stella One Design)

No time for hibernation!

There is no time to be wasted now - the sailing season is practically upon us!
Even over the Christmas holidays "Happy Return" was not forgotten, with new deck beams fitted for her cabin roof, as well as all those niggly details which come with fitting out a boat. Every piece fitted has to be thought through carefully; everything must work; everything has a purpose.
That is the true challenge of fitting out a sailing boat like this - it's all about function, practicality and safety.
You will notice how Rui has kept the interior of the boat as simple as absolutely possible to ensure easy access and comfortable moving space below deck. The galley has been sacrificed for more sleeping and sitting space.

Rui fitting the cabin roof deck-beams of douglas fir

Starting to look cosy: every piece fitted requires careful thought to ensure functionality and simplicity. Chart table to starboard, and battery storage to port

Deck beams have to be fitted with dovetails to ensure reliable strength for the cabin roof

 The plan is to upcycle this old hollow mast to the right. Happy Return's broken mast can be seen to the left.