The transformation of the Morgan Giles 30 from an empty shell to a almost complete expedition cruising yacht

Almost two years ago we were putting in the the first of the main bulkheads back into this Morgan Giles 30 after stripping out the interior and unbolting the deck from the hull to remake the flange joint which has failed and leaked. 

Fitting the main parts of the bulkhead it was time to fibreglass the top and bottom and then fill in the piece against the hull.

At the time is felt like a large area, however, that changed as more bulkheads and panels were glassed in place.

Over the past 18 months the owner as been building a new custom interior which will suit the cruising he and his partner will be undertaking in the future.

The interior is now almost finished with just few more items to be fitted before the inside will be insulted as the yacht will be going to the northern latitudes 

 

The deck getting the last few areas filled and then the deck can get sanded for a final time and the a final few coats of epoxy primer.

Using plasters tools it was able to fill larger areas and get a better finish so that we just have to give the decks a light sanding to get them flat and fair.

Just a few areas on the side decks 

A couple aras in the front and aft ends of the cockpit

 

Filling in an old vent opening in the deckhead

The hole was quiet a sizable hole which needed removing, so in order to do this a piece of Perspex was fitted to the underside of the hole to use as a plate to which the fibreglass could be glassed on to. So three layers of wetted out fibreglass was laid up on the Perspex and then fixed to the deckhead with a couple of small self tapping screws while the fibreglass cured. 

This is the plate fixed in position and being waxed the fibreglass will be able to be released from the panel once the fibreglass is cured.

because the underside of the hole as been ground into a slope on the inside of the deckhead the fibreglass will be flush with rest of the deckhead.

Once the inside of the deck head in cured then the upper part will have a slope ground on to as well and then more layers of fibreglass will be laid up on this side and then finally gelcoat over the whole area to be the same level as rg rest of deck and the two fixings holw will have fibreglass over the inside and then gelcoat on the holes on the deck.

 

Cabin windows refitted and the wheelhouse refitted.

Cabin windows back in place, however, these needed a bit of adjustment to fit as were a bit different in design and shape.

Using the overhead gantry was able to fit the wheelhouse back in position .

Protecting the roof skylight 

Lowering the wheelhouse back into position after the area had fresh sealant applied to the to the joint 

 

Starting to varnish the Rubbing Strakes and continue with the blue stripe gelcoat repairs

After applying three coats of mahogany stain to the the original and new rubbing strakes to get them to colour match as much as is possible it is time to start applying the several coats of varnish to the rubbing strakes.

The few coats will be a thinned coats of stain varnish followed by three coats of clear varnish to give te rubbing strakes a good level of protection. 

The rubbing strakes are looking better for every coat being applied as it builds up the levels of varnish

The blue gelcoat repair is coming along as well with build up of layers of gelcoat before kb=nocking back and compounding and polishing the whole of the blue stripe.

Just got to apply another coat of gelcoat before leaving it to cure over the next couple of days.

 

The Hardy Bosun new wheelhouse windows now fitted

The Hardy Bosun new wheelhouse windows fitted just a few other small jobs to do on the wheelhouse and it can be refitted to the boat once more.

Just got to clean off the excess sealant off the frames and remove the black protective tape and the window job will be finished 

Looking good with a new set of windows and now for the cabin to get her windows fitted.

 

The first stage in re-varnishing the finished Rubbing Strakes

Now that the Rubbing Strakes are finished as far as profiling and plugging the screw holes and shaping the aft ends to the original shape in was time to start applying the colour stain to make the rubbing strakes look as similar as possible to the original colour as they were when they were originally fitted.

The colour as given the rubbing strakes a uniforn colour along their whole length.

This shows how much the colour as changed over the years and even with a good amount of sanding the base colour was still a lot lighter than the new sections fitted aft on both sides.

A before photo 

An after photo as the colour starts to change the more stain that is applied,before the first of six coats of varnish to be applied to these rubbing strakes.