*siboney 2.0* structural repairs - 1972 58' yachtfisherman

[MarioG]

and more lamination

 

[MarioG]

the entire inside of the salon ceiling took approximately 3 months of 8 hour days, 5 days a week and a few weekends, and about 900 man hours of labor spread across a team of 5 people. In materials we used and burned out 4 disk grinders, used approximately 14 5 gallon buckets of resin, 2 full rolls of 1708, 1 roll of mat, about 20 gallons of acetone, lots of 4" rollers, 1 4x8 sheet of Cusa board. in total the entire rebuild of the interior fiberglass ceiling was just shy of $30,000, most of cost was associated in labor costs. I rate this job difficulty on a scale of 1 to 10 (1 being easy) this job was a solid 10 due to the physical requirements of hard demolition, working with your arms over your head. and an 8 for design complexity

In the end, the costs associated was fully justified and the structural improvement and the elimination of water intrusion into the boat essentially rotting out the boat from the inside out was factor made this part of the refit mandatory.

i must say that satisfaction and piece of mind that i have knowing that the boat is structurally sound is very comforting. as I look up at the new roof I see strength. perhaps I over did it by building what is essentially an up-side-down hull for a rooftop.... oh well, I've never been accused of being sane anyways.


PS..... there is a part two to this which involves the roof overhang that raps around the boat. more on that later.

cheers!

 

[brettportzer]

Wow, that is borderline unbelievable!

Thank you for sharing your projects!

 

[bostonhatteras]

I love it. Thinking well outside the box to find a solution. The mental stress is devising the answer for a problem you’ll encounter once, do once, and be 100% correct when done with no dead ends to make you back up. No small amount of thought involved.

 

[Flying Dutchman]

Nice work! Thanks for sharing!

 

[Timeless72]

Amazing!!

 

[johnjen50]

Wow! Incredible amount of work. When you’re done you will have a classic beauty that will have modern reliability, at a fraction of what the new yachts sell for. Aside from the fact that every time you roll into a new harbor she will be the queen and envy of anyone that loves boats! Question, the 30k, was that exclusive of the work you and the boys did? And did the 900 hrs include you and their time? Just curious. Massive project! Well done!

 

[Pascal]

Mario…. With all due respect, you are nuts

 

[edward]

I had a similar Ideal windlass on our Bertram. It was painted steel.
What a workhorse.

Is yours stainless plate or chrome??
It freaking looks great.

Oh, The deck looks awesome also.

That windlass looks like it came from TIFFANY ! Great work !.

 

[UNIQUE_NAME]

Mario…. With all due respect, you are nuts

incredible work and yes a 20 on a scale of 10.
doing my back deck was hands down the most miserable project ive ever done on a boat.
yours is bigger and much more complex, which has me in pascals corner....

 

[oldawg]

Amazing. The sagging roof was one of the reasons I moved on from my 58. Just couldn't figure out how to fix it at any reasonable cost. You have me wondering....could the top be removed, inverted, and repaired that way? We built oilfield boat hulls upside down.

 

[MarioG]

Wow! Incredible amount of work. When you’re done you will have a classic beauty that will have modern reliability, at a fraction of what the new yachts sell for. Aside from the fact that every time you roll into a new harbor she will be the queen and envy of anyone that loves boats! Question, the 30k, was that exclusive of the work you and the boys did? And did the 900 hrs include you and their time? Just curious. Massive project! Well done!

Hi John, THANK YOU! yes some of the labor hours included myself and my 2 sons was free. to be more accurate, my two professional laminators daily rate is $300 a day each. from there you can extrapolate the labor costs.

 

[MarioG]

Mario…. With all due respect, you are nuts

100% correct Pascal!

 

[MarioG]

Amazing. The sagging roof was one of the reasons I moved on from my 58.
Just couldn't figure out how to fix it at any reasonable cost. You have me wondering....could the top be removed, inverted, and repaired that way? We built oilfield boat hulls upside down.

could it be done? sure. But from my calculations, the fastest and best method was the one I used. I did contemplate removing the bridge with a crane and work the roof from the top down similar to what i did with the bow deck repair. in the end we was going to need to support the underside with studs to keep the roof radius in addition to the large square footage which would make the biggest patch in history. definitely its better done from the underside.

 

[bigbill]

i replaced about80 percent of my top from the top side using foam core and glassing the panels back in place. i did a 2x4 foot section at a time so i would have a surface to work off of. the area that the bridge screwed down to was plywood core for the screws to bight into so i didnt have to do that area, just had to dry it out. there were some sections that had previously been done so maybe the plywood area was done by a previous owner.

 

[SKYCHENEY]

Better than new!! Great job.

 

[rsmith]

Thanks for sharing. I’m sure a lot of people here are looking closer at their coring issues

 

[jmooney]

I was amazed at your first coring project , now I am truly shocked!

 

[rwaldrop13]

Having looked at all the photos and read all the comments, I am just overwhelmed with how lucky I was that Pau Hana didn't have this type of issue except for some small rot underneath the galley sliders. I was able to R&R the windows and repair that, and other than an occasional mystery leak in the salon that I was still working on (including epoxying screw heads, and a variety of other fixes), she was solid. Well until an entire marina's worth of floating dock sections slammed into her.

Beautiful work and the detailed photos are a terrific guide for DIY'er repairs.

Thanks for sharing.

 

[rsmith]

You might want to share the cnc data for other 58 owners since you did all that R&D it be a shame to lose it