Refit project update

Refit project update - Q1 2021

March 31, 2021

The refit of the Escargot has begun! After four months of hard work by the shipyard workers, we’re excited to share our first major update.

Our primary goal is to have the Escargot back in the water this summer for sea trials, which will allow us to work on the interior refit while afloat. The shipyard is tackling the heavy structural work, while we focus on planning the future: the electric propulsion system, the solar power generation setup, and the general electrical system rebuild.

Engine Bays Cleared for an Electric Future

The first major step was to clear out the port and starboard engine bays. The old, fiberglassed wood beam supports for the diesel engines have been completely removed. This opens up a significant amount of space for the new electric motors and battery banks.

The empty and cleaned-out starboard engine bay of the Escargot, ready for the new electric motor installation.

Below the Waterline: Fiberglass Repairs

All the necessary fiberglass work below the waterline is now complete. This included extensive repairs, followed by a protective epoxy coating.

Shipyard workers repairing the hulls with fiberglass. A close-up of the freshly repaired and primed fiberglass on the boat's hull. A starboard aft shot of the Escargot in the shipyard, showing the completed hull repairs.

A Fresh Start for the Electrical System

The complete electrical refit has kicked off with brand-new DC and AC panels equipped with new thermal breakers. We are currently assessing the existing wiring to determine what can be safely reused in the new system.

The old DC and AC electrical panels. The new AC electrical panel, showing organized wiring and new thermal breakers.

Rebuilding the Aft Cabin’s Curves

Restoring the unique rounded shape of the aft cabin was a challenge. It required building a custom mold to ensure the new fiberglass work matched the boat’s original and unique curvature.

A custom-built wooden mold clamped to the aft cabin to guide the fiberglass rebuild. The aft cabin during the fiberglass application process, with the mold ensuring the correct shape. The completed fiberglass repair on the aft cabin, showing a smooth, curved surface.

Aft Cabin Windows: A Thermoforming Test

It’s clear that most, if not all, of the aft cabin windows will need to be replaced. We experimented with in-place thermoforming of a methacrylate sheet to see if we could create new windows ourselves. While the result is acceptable, this process doesn’t quite replicate the original curvature of the glass. We are still evaluating our options here.

A sheet of methacrylate being test-fitted into an aft cabin window frame. The result of the thermoforming test on the new window, showing a slight curve.

New Supports for Grey Water Tanks

We have finalized the location for the new grey water tanks in the engine rooms. To prepare for their installation, we have built, fiberglassed, and painted sturdy new supports. The plumbing for the grey water systems is next on the list.

Newly built and painted white supports for the grey water tanks, installed in the engine room.

Planning and Design for What’s Next

Work isn’t just happening on the boat, but on the drawing board as well. The shipyard engineer has begun designing the superstructure for the solar panels. Before this can be finalized, we need to select the exact make and model of the panels, as their dimensions and mounting points are critical design details.

A 3D CAD model showing the design of the new solar panel superstructure for the Escargot. Another view of the 3D model, detailing the support structure for the solar array.