DIY Projects

An easy way to compute the do-it-yourself labor commitment involved is by timing how long it takes to scrape clean two 1-square-foot patches. The first is in the center of the least well-adhered paint; the second is in the midst of an intact portion of the bottom. Dry scrape each section with a thin-bladed putty knife and a sharp drag-type scraper, noting the time it takes to remove about 90 percent of the coating.

Our foray into sodablasting follows years of testing several different ways to remove bottom paint. Although you can simply attack the bottom paint with a power sander (an 8-inch sander-polisher is probably the most common tool for this purpose), this approach is messy, back breaking, and can expose the do-it-yourselfer to various health hazards. It can also lead to dings and divots in the gelcoat caused by overzealous sanding. Many yards prohibit do-it-yourselfers from sanding antifouling, or offer specific guidelines on how it can be carried out-often prescribing a chemical stripper to help contain the paint residue.

Testers applied dozens of exterior wood finishes (22 one-part varnishes, six two-part varnishes, 18 synthetics and satins/varnish alternatives, and eight teak oils and sealers) to small panels of bare solid teak and set them out to face the rigors of South Florida's weather. Two years later, our search continues for the ideal wood finish-relatively easy to apply, easy to maintain, lasts multiple seasons, and is affordable. Given that most wood coatings are rarely expected to last longer than two years in the marine environment-particularly in super-sunny locales-its no surprise that weve seen more significant changes in the coatings in the last six months than we had in previous checkups. With the exception of a few two-part products, the test coatings had lost their sparkle at the two-year mark, ratings slipped across the board, and weve come to accept that perhaps theres no Holy Grail of exterior wood finishes.

Practical Sailor often supplements panel testing with product challenges aboard our test boats to see whether top products still earn their keep in the real world and to try out new products. Two such evaluations are our exterior wood finish tests. In the January 2011 issue, we introduced a head-to-head matchup of varnish alternatives—market-newcomer PolyWhey from Vermont Natural Coatings versus perennial favorite Interlux’s Sikkens Cetol Natural Teak—that had been applied to our Cape Dory 25 test boat. For that test, we’ve just let nature run its course: no band-aid touchups, no maintenance coats, no freshwater rinses, no TLC at all.

Being a team of diehard do-it-yourselfers, we decided to try our own hand at devising a workable solution to defeating line chafe. After fiddling with canvas, old fire hose, and even messing around with some Kevlar, we settled on leather—an old rigger’s standby. It proved to be rugged and remained unholed after a ride on the belt sander. The fabrication process was kids craft 101, and there was something quite seafaring about the result. …

Being a team of diehard do-it-yourselfers, we decided to try our own hand at devising a workable solution to defeating line chafe. After fiddling with canvas, old fire hose, and even messing around with some Kevlar, we settled on leather—an old rigger’s standby. It proved to be rugged and remained unholed after a ride on the belt sander. The fabrication process was kids craft 101, and there was something quite seafaring about the result. …

Making spare winch handles is a sim­ple job for a competent metal worker. This I discovered because our Norlin designed Scampi, Windhover, has eight winches, all of which were manufac­tured before the world standardized on the 11/6" winch handle lug size. Since Windhover's 9/16" size handles are difficult to obtain and impossible to find at discount I went to Frank "Red' Grobelch, a superb metal­smith/welder of Waukegan, Illinois with some ideas for making up some spares for me. I'm so pleased with the results that I'd recommend the project to any reader who is a competent metal worker or has a friend who is. Even if you can use and buy standard 11/16" size handles, your mental state when clumsy Uncle Fred drops a han­dle overboard will be far more buoyant if you know you can easily replace the lost handle in your own shop.

Modern yachts are frequently adver­tised as having spacious cockpits: and, indeed, they do. But it doesn't take many afternoons of sailing to discover that the cockpit which seemed so splendidly roomy in the showroom or at the boatyard is too damned wide: it's impossible to brace your legs across the footwell without sliding down so that your body only contacts the boat at shoulders and tailbone. If you want to sit on the cockpit coaming while steering there's no place at all to brace your feet.

What do you do when the pin in the leg of your folding cabin table digs up the cabin sole? What do you do about the groove in the top of the teak toerail caused by your dock lines? What about the scuffs in the varnish­ed bulkhead behind the companion­way ladder? The answer is that you make chafe plates to solve all three problems. While chafe plates can be made out of almost any material — sheet PVC, thin stainless steel, aluminum — the most readily available and easily worked stuff is plain old brass. Brass can be purchased in many forms: sheet, solid round bar, pipe, tubing, and half oval, for example. It is quite cheap. If you have a local scrap metals dealer, you can buy enough scrap brass in various forms for $10 or less to keep you busy with a lifetime of projects. If there's no metal dealer at hand, most hobby shops carry substantial supplies of brass, although hobby shop brass tends to be thinner than what you want for most jobs.

Sealing the holes in decks where Loran and VHF antenna cables penetrate is a fairly common problem on modern boats. If there were only the cable to be considered, a hole of the appropriate size plus a dab of sealant would do an adequate if tacky looking job. But these cables in­evitably include sizable end connec­tors which require holes much larger than those required for the cable itself. Solutions include removal and reinstallation of the connector each time the cable is removed during storage or servicing, and any number of commercially available through-deck fittings or plugs. None of these solutions is simpler or better than the wood fitting shown here. It is attractive and can be made in a few minutes for a few cents.