Refitting Zephon

I bought Zephon in October 2011 and work began to refit her in the summer of 2012. The work consisted of:

  1. Making a new mast
  2. Removing all deck fittings, prisms and old canvas deck covering
  3. Removal of chain plates, pulpit and self-steering platform (pulpit repaired and all these fittings were shot blasted and hot zinc sprayed)
  4. Removing the Ducatti air-cooled engine
  5. Stripping paint to the engine compartment, bilges, cockpit and lazarette areas. All these areas primed with two coats of Jotun pink metallic primer
  6. Repairing the transom
  7. Replacing the port aft cabin corner post
  8. Repairing fore-hatch and main hatch
  9. Stabilising the deck structure Sanding and priming the deck
  10. Removing the centre Lewmar deck hatch and replacing with a circular deck prism
  11. Fitting and fastening 6mm, Elite ply to the deck. Underside and edges of the plywood was epoxy coated. When the epoxy was dry the plywood was bedded on tar and fastened to the deck with silicon bronze gripfast nails. The edges of the ply were screwed down with silicon bronze screws
  12. All nail heads and plywood joins were filled with epoxy and then the plywood deck was sanded and then degreased using acetone
  13. One layer of 300gm, woven roving was applied to deck using West System epoxy. The wetted out glass cloth was covered in peel ply
  14. Paint to hull was stripped
  15. Hood end fastenings were tested and where necessary replaced
  16. Garboard fastenings were tested and where necessary replaced
  17. Removal of all silicon which had been used to pay planking seams
  18. Caulking hardened-up and replaced where necessary, all caulking to garboards was replaced
  19. Graving pieces to hull and deadwoods were made fitted and glued using balcotan, polyurethane glue
  20. The hull was sanded using a long board to eliminate further unfairness being introduced into the hull shape
  21. All planking seams were payed using red lead putty
  22. Hull was painted with three coats of Jotun pink metallic primer
  23. Ballast keel was cup-brushed using an angle grinder and primed with three coats of a rust stop primer
  24. Worm shoe aft of the ballast keel was made from oak, fitted and fastened with silicon bronze screws, primed with Jotun pink metallic primer
  25. Replacement of rubbing strakes and toe rail
  26. Chainplates, pulpit and self steering platform were refastened
  27. The hull was painted with three coats of undercoat and two coats of top coat gloss
  28. The deck was painted with three coats of non slip deck paint
  29. All wood work was stripped and sanded and then oiled using Varnol Norwegian oil
  30. All fittings were fastened to the deck
  31. A second-hand yanmar 1GM10 and all sundry equipment was installed
  32. The mast was dressed, new nav lights were fitted and tinned ships cable used
  33. Two coats of antifouling applied

Please see my blog for full details and pictures of the refitting process.

Click on each image to enlarge it

Marc's Boats | email: marc@marcsboats.co.uk | 07824 996506 |