When the team of Yachtworks started to dismantle the deck, we realized that the balsa core of the fiberglass sandwich construction was rotten, so they had to remove the upper polyester layer, and reconstruct it with plywood. Later the whole deck was covered with polyester. The bases of all the stanchions, chainplates, tracks and clutches, winches, bowspirit and the pulpits were reinforced with extra layers of fiberglass with aluminium plates in between wherever necessary.
Although the original wooden bowspirit seemed very sturdy, we decided to replace it with an aluminium one because we could not trust the 50 year old wood. Our engineer Çağlar prepared a 3D tehcnical drawing of the new bowspirit to include every detail. It was constructed from 10mm aluminium plate by Murat Aydın in Tuzla, Istanbul.
Everything in the cabin including the cupboards, fridge, the head, hoses, electrical wires, batteries and tanks were taken out. Finally the boat became just an empty shell, except for the bulwarks that remained because Can Sürekli insisted on keeping the originals to ensure hull strength.
He also had our carpenter Fatih Şeren to prepare compartments for the diesel and water tanks which would also serve as an inner skeleton for the hull when covered with fiberglass. Selim made very precise, 3D templates from cardboard, computerized images were drawn from these templates by our engineer Çağlar and tanks were manufactured from 2 mm stainless steel plates again by Murat Aydın.
Contrary to all our doubts and fears, tanks fitted their places perfectly, and were almost incorporated with the boat’s hull. After building the cabin sole over them with plywood, our carpenter was able to start from scratch building the galley, cupboards, drawers and beds inside. We had many heated discussions about how to place the galley, the chart table and the beds so that Selim with his 188 cm height would be able to sleep comfortably no matter which way the boat heels. In the end we were able to fit everything necessary in the most practical way and in accordance with the GGR rules. We could even place a second fridge and solid teak table for the living area.
The cockpit and the companionway were completely redone. According to the GGR rules, the lockers were reconstructed to be totally waterproof. The cockpit base was strengthened with frames and everything was covered with fiberglass.
The old paint was removed and the hull was strengthened by extra layers of fiberglass. The bottom was painted with coppercoat.
The propeller shaft was removed, the kovan and pervane çıkışı were replaced, folding propeller that came from our boat Keyif was installed. The original rudder blade was sandblasted, strenghtened and covered with fiberglass.
In the meantime Selim was adamant on installing a hydrogenerator that could be lifted up from the water when not in use. Can had made a vertical tunnel for this type of hydrogenerator for our earlier boat, and Alubat OVNI 445 Keyif, and we had used it very successfully for many ocean passages. Now, he prepared another one for HDC, so that we could install our new Remoran hydrogenerator.
Our welder İbrahim manufactured the pulpit, pushpit, stanchions, holding rails for the cabin top and the companionway and the ladder on the transom as well as the skeleton for the dodger.
Our canvasmakers İbrahim and Sinan prepared the cushions for the beds, seats and leecloths inside as well as the cockpit cushions, and the sprayhood.
Cabin floors, cockpit floor and seats were all covered with synthetic teak.
To be continued……