Summary at a Glance
This is my Catalina 25 restoration project. This post, highlights how I cleaned, repaired, and finally got an older,
trailer-stored sailboat back on the water. I have documented many of the things
I came up against, everything from my sail repairs and engine work to fixing
the wiring, adjusting the trailer, and adding a few small upgrades. This is a
realistic look at how I brought a neglected cruising daysailer back into
sailing shape.
New to me boat
When I began looking for a 25-foot swing keel boat, I said, "No projects, I want a turn-key boat." Well, I guess those are famous last words (again). After running down the list of old boats and visiting several undesirable designs, I decided I wanted another Cat 25, a tried and true boat I have enjoyed owning before.
I have some news, I just picked up a 40 year old Catalina 25 that has sat ignored on its trailer for eleven years. I have owned and sailed five Catalinas, this is my second 25 and yes it is a project.
My cursory inspection showed a roller furled jib sail that fell apart in my hands and the furler hanging limp and sagging between pulpits, two of four winches wouldn't turn, two deep cycle batteries dated 2006, a broken solar fan letting in rain water, original cushions that are crunchy, two hank on sails in bags that look and feel new. Thankfully, the main sail looked clean and in good shape. Probably because it was rolled on the boom and stored in the cabin, still wrapped in its Sunbrella cover. Inside the cabin is quite a bit of white mold growing on the woodwork. I am sure there is a lot more to be discovered, but I saw no deal breakers and made my offer accordingly.
Let the project begin:
First thing I did at home was to empty the boat and use a shop vacuum to suck all the bilges dry and set up a box fan. Since it is March and raining, I rigged a tarp to cover the windows and companion way. I found a nice Danforth anchor with some chain and rode, I discovered eight brand new looking type four cushions, a large windex, The electric plug for the outboard, a porta potty. I found all the cushions except the big one for the quarter berth. I found a brand new, but old Standard Horizon scanning radio still in its plastic wrapper. (I immediately switched it with Kraken's radio) I did not find any fenders, which is too bad because all my extras are being used. I didn't find any dock lines or any extra lines for that matter, which means the one jib sheet will have to be switched around when I change sails.
Did I mention that moss was a half inch thick in places on deck and the halyards are black with something growing.
Did I mention that moss was a half inch thick in places on deck and the halyards are black with something growing.
A wet and wild and messy two hour pressure wash job made a huge difference but I accidentally got black hose marks all over the sides and gunwales making my clean up job needing a clean up job. BTW Soft Scrub takes off black marks easily, including bicycle tire marks.
Bear with me, I will edit this post later, but for now I'm simply posting notes as I proceed.
Brightwork:
Wiring:
The Honda BF8 outboard:
| This Is what happens outside |
I pulled the lower end off the motor and found the interior of the leg totally full of dead paper wasp nests. More shop vac work and a screwdriver to knock things loose. I removed the water pump housing and found insect larvae inside the pump passages and all around the impeller vanes. The vanes were permanently bent over. Again, I am glad I never attempted to turn over the motor. After a few hours of poking and probing with wires and string trimmer string, using the blow gun and shop vac, I greased up a new impeller and put it all back together. Lastly, I drained the decade old oil and put in fresh 10W-30. I've said before that during winter lay up I cover all my outboard holes and orifices with tape. This motor is a perfect example of how bad it can get.
| It's easy to see something's not quite right. |
| Yes it needs a new impeller |
I prayed the PO had run the motor out of fuel eleven years ago and then clamped the motor on my stand with the lower end in a plastic garbage can full of water. I connected a fresh tank of alcohol free gas, squeezed the bulb about fifteen times until firm and starting pulling the cord. After about ten pulls and a shot of ether it sputtered to life but there was no water coming out the tell-tale hole. I found a rubber hose I had missed and after some more probing water came out.
Ultimately I started and stopped the motor a dozen times and finally let it run at fast idle for one hour. I know from experience not to trust the motor, my fingers are crossed. For you mechanics out there, yes I checked the gear oil but didn't change it.
Galley water pump:
Sunbrella mildew:
Roller furler:
I stood the mast using a ten foot tall oak A-frame made from really skinny 2x2's and attached the furler drum to the headstay stem fitting.
| This system for raising/lowering the mast is fairly simple. I ran the four part tackle line to the jib halyard winch and cranked away. |
| The CDI factory recommends that the foil be supported with a strongback when stored, the reason is evident. |
Headsail:
Unrolling the 135 jib was a real floppy chore since the furler was so messed up.
| The leech is damaged for about the lower fifteen feet. |
| On close inspection you can see the fabric rotted next to the intack seam |
| Spreading a tarp over this simple frame made a shallow wash basin and the cleaning job doable but not easy.. |
After a week of drying, I stretched the torn and rotted jib out on my family room floor and using masking tape temporarily positioned it as best I could. Next I carefully positioned the fifteen foot long ten inch wide dacron repair tape and then peeled off the backing paper while using a wallpaper seam roller to work out the wrinkles. I have my fingers crossed that it will work and stay in place when furled. BTW, the tape was $40.
| With the sail rolled up you can see the clean white tape is partially covered by the many wraps. |
Mainsail:
Sail track gates:
Mainsail slugs that fall out of the track when lowering the sail for reefing is a huge nuisance and always at in opportune times.
Cutter forestay:
Cleaning sheets and halyards:
Trailer woes:
Using two bottle jacks and some planks I jacked the front of the boat off the trailer enough to adjust the front support, and then followed at the rear. Actually quite easy and fast. Now the keel is suspended properly when the cable is tight or may be set on trailer. Unfortunately eleven years on a poorly adjusted trailer has left minor indents in the hull. While working underneath I ground off a few rusty spots on the swing keel and touched up paint with hammered rust encapsulating paint.
As is often the case, the trailer winch looked much worse than it really is. A few squirts of oil and the mechanism freed up and works fine except the handle is missing. I will make a new handle but for now I can use the one off Kraken's trailer. The undersized kinked up cable is full of fish hooks waiting to get me. I will leave it in place at least until after my first ramp launch and retrieval.
Roller furler bends and twists:
| You can see the curved foil is tied between two chairs with a dowel. |
| In spite of the bent and splinted foil it rolls in and out easily |
I made a rather ugly homemade looking mount for the tiller pilot. The idea was to make something that did not protrude into someone's back while lounging. I have seen aluminum and stainless steel angle brackets that are back killers. My simple design took thirty minutes or less, used free left over components and lifts off for storage. I could have used a block of Starboard and still may if the wood mildews or something.
| The ideal mounting location doesn't quite reach the coaming and the light is in the way anyway. The seat is too low. |
Bimini:
The Bimini turned out to be a pain in the rump to install because it is so big it is hard to control with one person (Eight feet long and seven and a half feet wide) It kept jumping ship leaving black marks on my shiny old fiberglass. I wasn't sure of the height so I bought one too tall planning to cut the legs. Cutting the legs is fast and easy but you can't uncut what is too short so I raised the mainsail, attached the sheet and pulled the boom down as low as I figured was close hauled.
Rather than using the supplied rigid back braces, I chose to use straps front and back and mount it on sliding cars. I have done this trick before, it allows fore and aft adjustment which comes in handy when storing the top flat on deck or against the backstay. Not using the rigid braces also makes climbing on and off the boat less of a challenge because you can simply temporarily unclip an offending strap.
I really wanted to use Sunbrella but was unable to find a supplier with the dimensions and bows I wanted so I opted for a very cheap $162 including postage bimini. With proper care and a little luck it should last until the first accident or major storm hits. Then I will have more fodder to share in this blog.
Window leaks:
Success, on my last post heavy rain inspection there was no water in the tracks. Four or five applications of Capt'n Tolley did the trick. Now I can put the inside trim back in place.
Little things take time but need to be done:
Each time I get on the boat I seem to spot something. Today I dug out some flexible trim I have saved for years and began fitting it around the cockpit storage boxes. The U trim is way to narrow to slide over the 3/8" fiberglass so using putty knives I spread the vinyl clad metal and then glued it in place using ultra-clear Dap sealant (great stuff, works on rusty gutters too)
The galley sink hand pump still loses its prime in a day or two so I spliced into the line a $7 squeeze bulb. Now with two squeezes the pump works.
With the water system functioning again, I poured an ounce of bleach into the tank and filled it up and then pumped the treated water through the lines. If I remember I'll dump it all and refill later with two drops of bleach.
From my endless hoard of junk I found a left over roll of plastic floor pad and made a quick exact pattern of the inside sole. Thirty minutes later I was laying down a brand new piece of left over house carpet on top of the P/O's crappy indoor/outdoor carpet and adhesive. Wow, what an improvement and it feels good on the feet too.
I pulled the porta potty being careful not to let anything spill or touch me or the boat and tore it apart on the ground. Good news, after washing off the dust and figuring out how it works, it looks unused and in perfect condition. I scrubbed it with a sanitizing product and gave the two tanks the bleach treatment. With the head compartment empty I can address the ugly water damaged paneling.
I have noticed water stains and dried silt under all berths and storage compartments, it looks like the boat was allowed to sit with water about six inches deep. Neglect is a shame, total neglect is a boat killer.
Tiny cleats:
I have added four four inch cleats on the cabin wall, two on each side of the companion way. boards. I will use them to organize and secure halyards, furler line and down haul. Some boats hang bags, some have Velcro straps, my solution to the often tangled mess cost me $9.99 and works and looks better.
Vinyl stickers:
I have named the boat SUNSHINE and applied a eight inch tall four foot long decal to the side near the stern on each side. Sunshine was the name of my other Cat 25 so it seemed appropriate. I rejected Sunshine #2 as being pointless. Plastering a big garish name on an old boat takes twenty years thirty years off her age.
Mast lights:
While the mast was tilted down so I could work on the furler, I plugged in the deck plug at the mast base, the steaming light worked but the anchor light did not. After cleaning the brass connections I managed to get both lights to work but not at the same time. I think that means I have a ground and feedback issue. I've decided to ignore it, all I really care about are the red, green and white running lights and they seem to be functioning properly.
Dock lines and fenders:
I've managed to repurpose four fenders that I have been saving for rafting and cut up some old halyards for dock lines. I sill need to get five gallons of alcohol free gas and then I think I am close to a sea trial. I know better than to think the sea trial will be anything but chasing down issues but hopefully there wont be anything major like a seacock (two I think) breaking off.
Splash the boat:
I tried to launch without extending the trailer tongue and came up short, my last Cat 25 launched without extending tongue but this trailer rides the boat about a foot higher. I forgot to uncouple the surge brake line and ripped it off, ####. The boat floated free with about a six foot extension.
After tying to the float and parking the truck I pulled the boards and the bilge was dry, the Honda started with ten pulls of the cord and immediately idled fine. Two days later and again a week after that it still took ten pulls to start. (that's about eight too many) I ran it wot for ten minutes, the boat achieved 6.75 knts through the water. Apparently the paddle wheel knot meter works and so does the depth sounder. I checked the electrical output of the outboard and it was charging the battery and so was the 12" x 30" solar panel. I mention all this because I normally don't expect anything to work and was really surprised. Add in the facts that I got the running lights and radio working makes my low purchase price a very good deal. (we'll see)
After ten minutes at wot the engine began slowing as if fuel starved, backing off a little cleared it up. I plan to switch tanks to see if that makes a difference, we'll see.
My third visit to the boat. I plugged in the new Simrad tiller pilot and it kept me headed up while I hoisted the main in light winds, no problems. Next I unrolled the damaged and repaired head sail, again no problems. Five minutes later I pushed the tack button and the tiller pilot put the boat in irons, oops.
Fours hours later as the sun lowered I wrapped up a pretty enjoyable evening sail. I checked the battery and found the voltage still topped up. I put the blue Sunbrella back on the main and hatch and went home with a full bottle of wine.
For my next outing I will try to remember a corkscrew.
Later, I short tacked the rest of the way around the island and when the wind piped up I wanted to reef but alas, I had rigged the tack reef line to the first set of reef points and the clew line to the second set of reef points. Unable to reef and being short handed by myself I took a few nasty gusts laying me over way more than I am comfortable with before dropping the main, the autopilot sure came in handy so I guess I wasn't short handed afterall.
A few days later on a calm afternoon we cast off for dinner and wine, I never raised the main but did unfurl the jib after struggling with the bimini top. We sailed and then motored and I intentionally ran the boat aground in a sandy creek bed so we could enjoy dinner without the trouble of anchoring. Putting up the bimini saved us from sunstroke and I determined I need to shorten it by about four inches to clear the boom. All in all, I'm happy with the boat and it didn't turn out to be that much of a project afterall.
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