09 November 2017

The Deck

We reached a significant milestone in our restoration of Petronella, our Joshua 40 steel ketch. The hull! It's finally done!

Hull painting complete!
How much paint does it take to completely restore the bottom and topsides of a 40-foot steel boat? Approximately 20 gallons, all told. That's off the top of Howdy's head. I will get the total when we are done, just for curiosity sake.

Originally, Helena and I planned to take care of the deck ourselves. I mean, how hard could it be? It's just paint, right?

But after seeing the quality of Howdy's work, and how fast his crew works, I realized that there was literally no way that we could do the deck work ourselves and achieve the same level of quality. Not only did we not have all the required skills, it would take far too long to do the work. We'd be lucky if we finished by spring.

Skills, you ask? Yes. Painting is a skill. Especially using the new epoxy paints. Having owned a wooden boat for nearly ten years, I thought I new how to paint. Let me tell you, compared to these guys, I know nothing. Seriously. I painted the insides of the four deck hatches, and I am embarrassed to compare my work with Howdy's. It's an order of magnitude difference.

And since we are here and have Howdy's attention, we are grabbing the opportunity to get the job done right. It might cost a little more (not sure about that, when you factor in all the costs!), but they are doing a much more thorough job than we would ever contemplate.

What kind of things are they doing? Just focusing on the big jobs...

How about sanding off the top layers of paint, including all the anti-skid. Two days on knees with a heavy rotary sander. I don't think I could even have done that! Here is the deck sanded, with the first coat of primer.

Deck sanded and primed
We liked the look of the white deck so much that we almost decided to go all-white, but Howdy convinced us that it would show the dirt too much, so we will be tinting the non-skid areas.

Another big job that really needed doing, but we probably would not have tackled ourselves was the whole cockpit/hard dodger area. Did I say big job? Big job.

Cockpit prepped for sanding
My part of the job was to remove as many of the electronics, floor boards, seats, and other bits of hardware from the area, to prep it for sanding. That alone was a big job.

Note that the old plexiglass windows are removed. They were so cloudy and scratched that they were nearly impossible to see through, even on a sunny day. Next to useless in the dark or bad weather. They have been binned and will be replaced. Helena and I are tackling all the cockpit teak, but will discuss that in a later post.

Can't wait to see how this sub-project turns out!

And then there were the Dorade boxes... We had seen some rust under them. Now it was time to find out where the rust was coming from. It didn't take long to find the problem.

Dorade vent, with box removed
The Dorade box (not shown in photo) was held to the deck by two stainless steel brackets, screwed to the deck. Unfortunately, these had not been re-bedded in some time, so the bedding compound was literally gone. Water got between the brackets and the steel, and rust began its insidious work.

Howdy's crew removed the brackets and repaired the rust damage. They will make sure the new brackets are bedded down well, to prevent future problems.

Bedding compound, people! As I have said before, it is not forever. Get out there and re-bed something on your boat today. I guarantee something is leaking on your boat if you have been ignoring this problem for several years. Particularly fiberglass boats. Don't be lazy!

Okay, rant complete. But seriously, every real problem on Petronella has been directly tied to old or missing bedding compound. Think about it. An ounce of prevention really is worth a pound of cure.

So, that is where we are. We'd hoped to be done with the deck work this week, but bad weather has held us back. Fingers crossed for some good weather!

Next Up: Heading South, Finally!


  1. Absolutely 100-hundred-per-cent-agreement - DON'T "push" the boundaries... Doesn't matter if it is red-lead/timber, epoxy/ply, epoxy/foam, triple diagonal laminate, epoxy/steel, stainless steel/aluminium - the boundaries/penetrations are always the point of failure. Just don't stick in a bit of kitchen silicon because it was handy on your tool box when you added that extra widget to make your life easier - you just made life harder down the line. Bed properly. And re-bed regularly. Works well for the cruising "other half" as well.

    Ask me how I know...

  2. Boat looks REALLY GREAT. When you all passed thru Cape Fear headed north I looked at the various little rusty nooks and crannies, crossed my fingers and hoped for a good outcome. In fact it is a truly GREAT outcome for many many YEARS to come. Awesome&Congratulations !!!

  3. Yes, she needed some professional TLC, and I’m glad we were able to give it to her. She may be the best Joshua 40 afloat at the moment.


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