Sea Hound, a 24 ft Husky class motor sailer damaged railings.

Starboard side railings broken off after the vessel's mooring ropes were let go by vandals allowing the boat to drift on riverside at Wareham & receivedhusky 24 railingcontact damage. Insurance damage repair

Most of the rail already missing. Click on picture to enlarge




Above & below: All railing removed & deck edge overhang ground off


husky 24 railing


The original design was somewhat inconsistent so new simple design rails & toerails were machined up. The bend fwds was thought too extreme for cold bending so a steamed pre-bend was put onto the timber. Iroko steams reasonably well. Click on picture to enlarge Railings 2" x 1" & steam for 1 hour then immediately set the bend.




bending iroko




Because of the stanchion bases it was better to fit short sections of toe rail at intermediate positions, both fastened & bedded on MS polymer Click on picture to enlarge Railings awaiting cleaning up & plugging Railings nearly fully fitted. Click to enlarge photo.


Most timbers will bend adequately in a cold state for the average vessel. although some, like this one, have a severe bend both curved upwards & on the flat causing risk of breakage. If fitting new railings start at the front & carefully align the rail gradually as you move aft. Fasten at each point & do not let the rail spring out or else it will break.

A steamer can be simply made by using a wallpaper stripper to feed steam into a length of flexible air conditioningg/heater ducting. This is convoluted & extends for most practical purpose adequately. Additionally it can be used for bent timber as well.


Sea Hound, a 24 ft Husky class motor sailer damaged railings.


Bend successfully located without too much strain on fastenings

bending rail










Railings nearly fixed but not finished Finished & oiled & plugged Iroko when newly sawn is quite light in colour, but after a few days of UV light becomes almost the same colour as teak








The Blue hull has been previously painted & the owner will make good the paint here










LATEST: since the above work was completed under insurance, the owner asked if I could improve the port side without replacing the railing as this overlaid railswas in very poor condition. To keep costs down the port side has now had a thin section laid on the existing railing which was beyond restoration & new toe railings have been fitted . Substantial visual improvement without major replacement. Port side with new outer railings, note that the rail is planted on the outside of the original to save costs following the owner's request to minimise expense but to maximise looks. New toe railing fitted to match stbd. side

Other shipwright & marine related services that I am able to offer:


New joinery-- tillers--deck repairs-- ferrous fabrications & galvanising-- rubbing strakes-- handrails-- Just ask for a quote


Solid oak drop leaf cabin table with bottle rack


oak cabin table

oak drop leaf table


This is a solid oak drop leaf table made tp order for a particular vessel & it is higher at the aft end than at the fwd. because of the cabin sole rising. The design is our own







New galley design


new galley


This is a complete new galley design & construction on a 12 Ton Hillyard, the old galley was a linear design with the cooker fwd. The space has been utilised for practicality & modern upgrading.








Bronze pattern making & machining


bronxe casting


Machining a bronze casting after having made the wooden pattern & sent off for casting in aluminium bronze at a foundry in Bridport, Dorset. This was one of several castings required for this vessel to hang the rudder on.


I can also produce welded steel assemblies such as stanchion bases to one off design & send off for galvanising.

All I require is an accurate pattern or drawing





Rudder investigation & repair


grp rudder




This is a rudder from an elderly 4/21 sailing cruiser, originally fitted with steel tangs (rods) fitted into a bronze stock. These had completely rusted away. New stainless rods fitted & the rudder rebuilt












Structural repairs.


rotted sidedeck


A Heard class heavy GRP sailing vessel, built in Falmouth, but with a plywood deck with teak over the top,The teak had leaked & the ply rotted along with some of the supporting structure. New plywood deck & supporting structure reinstatements.








Yachting World 5 tonner hull damage repairs

The vessel had been severely damaged whilst on her mooring outside Weymouth Sailing Club in that all of the starboard side of the hull and structure has been subject to heavy abrasion and collision with the moored alongside.


damaged deck

ripped stanchions damaged hull










This resulted in substantial areas of badly damaged paintwork, broken rubbing strakes and toe rails, fractured bronze chain plates and various stanchions and stanchion bases ripped from the deck. fractured bronze chainpletse


The old bronze chain plates were removed including the fractured one and these were made up in mild steel, 5mm and drilled precisely as originals and sent away for hot dip galvanising. Various stanchion bases were removed and, these also had to be made up in our workshops as this pattern is no longer available.

new rigging plates


Again, these were sent away for hot dip galvanising. Hot dip galvanising should last a minimum of 15 to 20 years and sometimes more and, in the case of bronze chain plates that have been flexed, substantially more reliable as, bronze cannot be relied upon if it has been subject to Bending and straightening as was the case here.




yachting world 5 tonnerThe new chainplates were bolted down on a base of polyurethane sealant. All of the new stanchion bases were bolted into position with appropriate shape deck pads beneath to set them at the correct angle. The old rails were completely removed in their entirety and new sections of rubbing strake and toe rail machined up in mahogany to match the original. These new railings were fitted into position, all fastening heads were pluggedand the timber faired off. The topside coatings were in very poor condition as, there have been a substantial build up of coatings and, where it had been damaged and scraped back to the wood there was a substantial edge of paint to be faired away before any finish could be possible. All of the starboard side was prepared for undercoat, faired off and rubbed down and top coated. All of the varnish work was finished with four coats of varnish, two new stanchions were fitted and finally new guard wires were fitted to complete the job. Undercoated, glossed & gold line.


The finished vessel ready for launching


yachting world 5 tonner












Fitting portholes & window piercings in new Wanderer class built by Lowestoft IBTC

All portholes have been made with a spigot that is too long & will have to be machined off. bronze portholesIn total 8 Portholes & 4 rectangular timber frames are to be fitted.

The cut outs are 6" dia & have to be cut with an adjustable hole cutter in situ as internally there is no room for jig saw base plate to turn as is the case externally








bronze portholes


Temporary checking to gauge required spigot length, too long at moment.







Below: all portholes fitted as above . Very little room spare internally for hand tools.



The remaining 6 holes will have to be carefully marked out & 4 rectangular holes cut out. The original builders have installed vertical bronze rods through the thickness of the coachroof adding to the positioning difficulties.

All portholes spigots machined off & now fitted, just leaves the rectangular timber frames to make & fit on the aft end each side (2 off per side) Cutting the rectangular piercings has to be very accurate to line up with the frames & is also very risky as there is no room for tiny errors as these cannot be hidden or obscured.




iroko window frames

window blank


A blank is produced to the size of the aperture & this fits the timber frame. It is offered up in the frame so that the coachroof aperture can be carefully marked for cutting.

Measurements & visuals must be used, never rely totally on measurments without checking visually. The eye picks up minor mistakes in measurements very quickly.




The whole assembly is offered up & positioned where appropriate on the coachroof side inside & out. Four cornerholes represent the hole cutter positions to form the rounded corners of each window. These are then joined up, the outer edges rebated & the inner corners moulded .

four corner holes

window piercing


A considerable risk in undertaking this type of work as one mistake & several thousands of pounds worth of teak coachroof is wrecked!







Finished internally & externally



wandere 30 timber coachroof

inside wanderer











Trapper 28 Hull skin damage & gel coat spider cracking/hard spot cracking

A photo series of repairing major cracks in a Trapper 28 hull by grinding the gel coat away & the first layers of laminate, epoxy resin & glass cloth laminates, filling & surfacing & finally spraying to complete. Note how deep the cracks are in the opening photos. These spider cracks were of unknown CRACKED GRP HULLcause but were picked up on survey when it was suspected they were deeper than initially thought. Identical damage was present on the other side of the vessel.

These cracks will not return as they have been reinforced, but merely filling cracks such as these will not permanently obscure them, they are usually a sign of major stressing & perhaps laminate damage. Initial removal of gel coat highlights how deep the cracks go. On both photos they can be seen extending below the gel coat. At the vertical section in this photo (right) is a hard spot crack over a vertical internal division where the crack was very deep, never ignore hard spot cracks as they can be extremely weakening in some cases, particularly over main bulkheads.



grinding out cracks in gel coat & laminate


These cracks will have to be ground out as the lamainate is damaged &

weakened. The process of grinding the gel coat away & bottoming out the cracks , when this is complete, increasing widths new laminatesof glass cloth & epoxy resin laminates are eventually layered into the prepared sections.






The Area is sealed with polythene to keep moisture out whilst curing. It can be clearly seen where the gel coat has been totally removed Next the area is surfaced with polyester filler & reshaped, this is time consuming with large areas such as this.



Psurfacing fillerreparation for respraying has to be perfect if a good finish is to be achieved. This is where a great deal of labour intensive work & therefore cost is involved. The repairs are stronger as the new laminates also replace the non structural original gel coat. Finally the area is re sprayed to match with 2 pot polyurethane, this paint has to be tinted to the right colour as it is unlikely that a standard "off the shelf" colour will match. The identical damage was also repaired on the other side.








The finished hull



trapper 28 gel coat repairs














Westerly Griffon rubbing strakes improvement


The Problem


The original rubbing strakes had been planed down & the fastenings were just appearing as the plugs were now too thin & coming off. Additionally there were black stains around these fastenings that could not be removed. blackened fasteningsTo remove the railing or the fastenings on Westerly models (Centaur, Konsort, 33, Conway Longbow,Renown, Pageant etc.) is almost an impossible job to do without spending an enormous sum as they are overlaminated internally & many are behind linings & furniture. To access these is prohibitively expensive. Especially considering that they are spaced every 6 inches.

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The solution:


Unfortunately the original square edge rails had been rounded off, making the laying of an simple overstrip impractical, so the only method possible was to rebate the top & bottom edge of the rail & produce a new overlay strip in iroko with a matching ploughed groove which is not particularly easy.

rebated rails

A router was set up with a bearing cutter to rebate the top & bottom of the railing (see photo) Westerly Griffon Rails Rebated original railings easily seen.




Easily seen here, the damaged corners have been carefully rebated & the rebated railrail is ready for a new section of precisely machined iroko to fit onto the old rail making the whole rail as good as new.














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overlaid railing


New railings starting to go on bedded on MS polymer.







Railings finished & looking as new again without having to remove the originals. The other advantage is that the original scarf jwesterly griffon railingoints which are always prone to failure, can no longer move & come apart without having to remove the originals.








The finished job


westerly griffon finished rails