⛵️ Abandoned DIY hurricane catamaran project. Lots of leaks! 😱

Welcome back aboard the hurricane-damaged DIY Terry’s 44 Catamaran project. Join us as we dive into an extensive refit, tackling leaks and making critical repairs.

Significant Challenges and Solutions

Upon arriving at the catamaran, we immediately identified a major crack in the cabin top, allowing rainwater to drip inside. We also noticed multiple cracks across the deck and an open port light in the forward port head that significantly contributed to water leakage.

Fiberglass Grinding Technique

To tackle these issues, we utilized our favorite grinding tool – an angle grinder with a dust shroud. We prefer this setup due to its efficiency, affordability, and excellent dust management capabilities.

Foam Core Replacement

Upon inspecting the damaged area, we decided to replace the foam core. By using an oscillating multi-tool, we efficiently removed the old core and inserted a new piece, ensuring a strong bond with epoxy.

Pump Station and Epoxy Application

TotalBoat generously supplied us with a pump station, which significantly improved our mixing efficiency. We applied thickened epoxy to create a watertight seal while keeping water out of the cabin.

Fairing Compound Application

For cosmetic touch-ups and achieving a smooth surface, we applied TotalBoat fairing compound. We made sure to address both high spots from fiberglass buildup and low areas that needed raising.

Testing Sealing Materials

We conducted tests on various sealing materials, including duct tape and mystery tape, to determine the most effective solutions for temporary fixes around the boat. Mystery tape proved to be an excellent alternative for its resistance to UV degradation and absence of sticky residue.

Leak Hunting

To identify additional leakage sources, we kept a vigilant eye during rain episodes, recognizing that leaks are often highlighted in the presence of water. Our ultimate goal was to make the necessary repairs to prevent water intrusion while focusing on long-term solutions for sealing cracks and openings.

Through meticulous repair work, efficient use of specialized tools, and strategic application of epoxy and fairing compounds, we managed to minimize the leaks within the catamaran. Our commitment to creating a watertight and resilient vessel allowed us to progress in our refit project while ensuring safety on board.

Future Plans

In upcoming videos, we will continue documenting the repairs and share our experiences with you. Keep an eye out for more exciting updates from our catamaran project and the adventures on Athena.