Rebuild to 'Round the World' Southern Cross 28 Inspired Insanity
From Delamination to complete rebuild of a Southern Cross 28 Sloop to Sail the World, 2 Stops around the World Via the Southern Ocean and Her Capes...
I
had a dream of sailing around the world, a troubadour with guitar and Irish
whistle in hand, hippy of hippies, spreading caring and love as I would
go.And you say, “Are you for real?”Sure I am.Yet, despite the whimsical appearance of such a dream, there is nothing
fairy tale’ish about doing it.I was a
new to sailing in 1999.Little did I
know when I bought Tryst, a 1982 Southern Cross 28, that in November 2005, the
dream would actually bring me to sailing solo RTW with just 2 stops in the
southern hemisphere. NZ and Tierra Del Fuego.There was no concept of sailing around the Capes when I started. I was
going to gallavant around the world though certainly planning to cross oceans.Tryst, later named Inspired Insanity, had
been sitting on a dock in St Thomas for 7 years without going for a sail when I
first saw her. She looked like a little apartment.Cute curtains, upholstery, ceramic dishes, a v-berth master
bedroom.My boss at the time, knew the
boat and the owner.He said it was the
right boat for what I wanted to do.He
vouched for my employment and I was able to finance the boat over 3 years.Taking his word that it was the right one, I
never looked at another boat.I sensed
she was.Tryst and I had one of those
bonding moments right at the start when while excitedly showing her to a
friend, put my foot on the salon floor to feel inches of water under my
feet.Luckily, we had put a new battery
on the boat for the survey and managing to remember where the bilge switch was,
she was saved from sinking that very night.My brother who had seen the sparkle of life in my eyes when I started
sailing in 1999, put up the down payment and a start to reparations. She was
mine.Newly divorced, 3 grown kids, I
was going to sail the world.
There
was the obvious repairs to make from damage and age issues.She was at that golden age of 20 years and
hadn’t been seriously sailed for the last 10. Hurricane Marilyn had done some
damage.The haul out of the survey
revealed a soft area in the keel but other than that, not a blister to be
seen.Strangely, a woman, wandering
through the yard one day, a bit disgruntled, stopped only long enough to say “I
wouldn’t pay 10 grand for that piece of shit boat” and she kept walking.I wasn’t hearing any of that then. I was in
love and this sailboat, my dream ticket.
For
the survey, the systems seemed to light up, but it wasn’t long before the lack
of use and infiltration of water into the wiring and instruments was
revealed.The depth sounder,
autopilot, wind meters and knot meters all shut down.The storage locker was full of safety equipment, inverters, a
wind generator.They were ceased,
rotten and no use to me.I had trusted
the experienced eye of optimistic people who genuinely thought this gear would
be good but now I would start from scratch.I had a partner at the time whom was more than handy and willing to
teach me.We tore that boat apart.Every piece of rubber, every pump, even the
transmission seal was no good.We gutted
her to and started to rebuild.She got
simple real quick no longer being built to look pretty but to house one person,
with musical instruments, and sail oceans.I never put the electric pumps back in, or the ACv system, nor did I
replace the boat’s instruments.I was
content to have a handheld GPS and take a chance in shallow water.But when it came to the rig, it was
different. Having already planned to do ocean crossings, I made sure ‘Skip the
rigger’,at Compass point, made the rig a degree or 2 bigger than standard for
the SC 28’. New lifelines and a new bow pulpit.I used old parasailing launch line for halyards and sheets.
Her first real run was to Margarita
and then on to the Venezuelan coast, Trinidad and up the Antilles. We arrived
back in Nov. of 2001, in good shape but I was starting to feel my oats and my
desire to venture off and discover was pulling me on. I had a spiritual score
to settle with myself.Loving to play
Irish music, an avid session player when stateside, dreams of Ireland were
dancing through my head. I would sail the world gently, short hops.Bermuda, Azzores….
The
only real issue we had found on the trip south was breaking stainless
fittings.I vowed to turn them all out,
chainplates and all.I would need to
fix that soft keel and get a steering vane.I went into Indpendent Boatyard with a 3 month plan.
Somehow I managed to splash
her again in just over that, but no one could have imagined how I would make
it.The plan had been to let her dry
out for 6 weeks before grinding away at the keel.My ex husband had a canoe building shop in NY for years and we
had built our house.I was familiar
with composites and woodcraft shop tools, but I became best friends with a 10oz
Makita grinder leant to me by the friendly wooden boat restorer 2 boats
down.By the time I got out of the
yard, I wore it out, owing him a new one, as I had ground the whole bottom of
that boat a dozen times.The intial
attempt to grind out the soggy cloth on the keel revealed a wet unending delaminated,
osmosis nightmare that covered the entire hull of the boat below the water
line.I was angry now.Not at the old owner.He didn’t know.But this whole dreamy eyed idea of sailing the world was really
getting screwed up.I had muscles as a
fitness trainer and enough experience with composites that there was no way I
wasn’t going to fix the hull but I wasn’t happy with God, who ever he was…at
all.The words of the woman in the yard
that day, who I later found out was Cat, the owner of an older hull SC 28’,
came back to me.The next time I
crossed path with Cat, also a solo sailor, she explained that my boat’s hull
number was the first built after a change in the relationship between the
builder and designer. There were questions about the newer boats
structure.She had serious deck hull
joint issues with her boat that left her nearly sinking on a crossing from the
Canaries to the Carib.When she walked
by that earlier day in the yard, she had just had to have the joint
repaired.There were weak spots in this
boats design and build for a true bluewater boat.
I worked like a crazed person
gaining nicknames like Amazon Woman, the Energizer Bunny, as I tore the hull
off the boat and put a new one on, working 7 days a week at a dive shop, playing
music 3 nights a week and grinding from 10pm to 3am.Even the folks living on boats in the yard seemed to understand
my need to keep working.I had stripped
the layers of glass down to the core on the midships on the port side, and the
first layers of mat and roving the rest of the hull.Areas of the hull at the stern of the keel where the bilge was,
had bearly any glass at all. Thank goodness I never hit the keel there. Glass
without resin, resin without glass. The rudder skeg was full of mud.I had to grind until I got to something
solid to glass to.That meant taking a
skill saw to the keel at the bilge, as there was no way to prep and resurface
the inside of the bilge from the inside.I got good at cutting big holes in the boat and rebuilding them.But it worked.I used polyester resin for the major foreward and belly of the
boat layers, but once I was rebuilding the keel and the stern, including the
rudder skeg, I did it all in epoxy.I
only did one faring as she wasn�t a race boat and to make it gel coat smooth
would take an exponential amount of time. Then the layers of coatings, and
finally bottom paint.Once I had the
major repair accomplished, I had the energy to look with fresher eyes at the
rest of the boat.The bow stem was
bugging my conscience.It was the only
stainless that I couldn�t inspect as it went through the hull, then was glassed
into the bow.Finally, my intuition
won.When my partner cut off the
visible piece of the stem, it fell in 3 pieces in his hand.It was rotten.What a terror that was.Imagine if I had not decided to replace it.But what a mess we made.We had to cut the whole bow out to get the stainless out of the way so I
could bolt through the new stem which I did as a traditional front piece.I was so intent that I had the work done by
10am the next morn. My partner, allergic to epoxy and dust, was doing other
work, seacocks and new rail.I knew the
delamination was also in the topsides but I thought it was not structural and
repainting the topsides was way over my head. Somehow, purely by the brawn of
determined anger and helping hands, that boat splashed in April.I was broke. The yard owner even felt bad
and gave me a break.The builders in
the yard sold me materials at cost.There was a going away party for me the last night that Morgan Rael and
I played music at Bottoms Up for a standing room only crowd.Boxes of treasure from everyone�s last
cleaning of the Bilge lined the pub. Plus lots of other new stuff.I found a used steering vane.Pete found me a used radio� I was set.
From St John�s Coral bay, I was off
to RI, my first solo sail.4 days out,
enjoying the SSB, David Jones was doing the morning net telling every boat to
get off the ocean.A big gale was
coming.He got to me, paused and said,
�Donna, you are just too slow, you are going to have to sail through this
gale.�When I went to transmit a
response, the radio blew, not just a fuse� It was dead.7 days later I arrived in RI.2 major gales, the prop spun off, alternator
died, as of course did the radio.I
determined I wanted a 3rd reef in the main.I made my repairs in Bristol thanks to a
good reference in Rabbi, great folks in a great town and some gigs playing
music to fund me.
I left RI July 14th only to have to return right
away.The alternator, just rebuilt, was
not putting out over 12v.They hadn�t
changed the diode� fancy that. Well, a few more days and I took off. After a
week of trying to make contact using the radio, I realized that despite the
fact that Cay electronics told me she was fixed, she wasn�t transmitting.Herb couldn�t hear me.Neither would my mom�s friend who was
suppose to track me through my checkins.The first real storm I did out there was 40� seas, a force 9. It took
out my steering vane, and mainsail.I
had to make a choice.Would I go
back?With no self-steering I was going
to have to be on the deck 24/7.I had a
spare main sail but it was the top of a bigger sail and only had one small reef
in it.I learned to rig up the tri sail
as a 3rd reef main for storms. I steered for 24 days without any
true sleep.33 days after leaving RI, I
arrived in Baltimore Ireland, brought into the harbor by the Royal Life boat
because my fuel was contaminated and clogging the only filter I had left.They weren�t anxious to do a real rescue if
I got into trouble in the harbor.But
now the repairs began.
It was while in Ireland that I
discovered the extent that the delamination effected the deck hull joint.I took 100gal through that joint one day when
I went aground behind Sherkin Island. Inspired Insanity ended up on her side in
a few feet of water given the 20� tides there.It was a godsend in the end.I
rebuilt that joint on the inside of the boat grinding the entire length of the
hull inside and filling it with epoxy and biaxial cloth to prevent water from
coming in but I knew water was still getting into the joint from the
outside.The fix wasn�t structural
enough either.A friend had made some
stainless knees to help support the rail where the jib tracks laid on top.I left Ireland with patched up sails, hull,
radio, steering vane with a newly inspired desire to go longer offshore, to
NZ.I left Aug 24th.We hit a huge storm, 45�seas and force 11,
west of the Biscayne, a real eye opener for me. By the time I made it to the
jumping off point in the Cape Verdes Islands, 28 days later. I knew the boat
wasn�t ready for the Southern Ocean.I
headed back to the Carib and finally RI to do the last refit before actually
setting off to sail half way around the world non-stop to NZ.
Aug 1, 2005: Now the refit was full
on.Even if I was postponed because of
lack of funds, I had to have a new steering vane, wind generator, new sails,
but more so, I had to tear that deck hull joint apart.There were bad areas around the stanchions
where water got into the balsa core of the deck. In the end I also found huge
issues with the structural backing to the backstay and the core under the
mast.
The deck hull joint on a SC 28 incorporates a 4� tall
scupper the full length of the boat.The actual joining is the flat top of the scupper where the deck and
hull meet at a right angle. The jib track is laid on top of this 2� wide
over-hang covered with a �� cap rail.The idea was to get the track as far out as possible but the stresses of
the jib sheet against the track are great and had destroyed the integrity of
the glass as it flexed continually.The
jury rigged knees made in Ireland to support the rail were already showing
stress to the hull where the knees were anchored as the rail was flexing that
much.The hull was delaminated and
rotted at the joint edges.I wanted the
fix to reinforce the whole joint so to compensate for the 90deg angle,
essentially making it more solid to the scupper and from the scupper to the
deck.After 5 years of contemplating
the troubles with this joint, I had decided I really wanted to wrap this whole
joint, from the hull, up, around the top and back down the scupper to the deck.I knew having worked with glass that it was
going to be really tricky to get the glass to take the curves. My ex husband
came to my rescue.Taking the project
to his shop, he created models and a special set of clamps to allow us to wrap
the joint with glass and then use the rail as a mold to encapsulate it. .
First, I tore the deck hull apart, putting a grinder through my chin at one
point, I have to say, having used the wrong tool for the job I was doing.The gel coat had to be ground from the deck
up the scupper and down the hull about 8�.My son epoxied the joint together using cloth and thickener in the
joint.Then the complex curves of the
deck hull joint were wrapped and saturated with epoxy using tropical slow
hardener.We used 3 separate pieces of
1 ��brazilian cherry, one on top, one outside and one below, clamped to be able
to form around the joint, and then bolted through the rail to secure the wood
to the glass while it cured.It is
heavy but it is solid as a rock.
With the help of the original builder, Clark Ryder, I
determined that the mast step may have some core issues so I used a floor jack,
normally used to secure basement ceilings, under the mast as a compression
post.At that time, Clark told me that
the SC 28 was really built as a �coastal� bluewater boat and certainly not to
sail the Southern Ocean.The SC 31 that
Pat Henry sailed the world in, was built more for a RTW sail, having a
compression post and built with more reinforcement to the deck fittings.
The
rebuild continued with the deck at the stanchions, fiberglassing the rudder and
rebuilding the bearings.I had rebuilt
the skeg during the delamination build.A new Cape Horn Steering vane, Pacific Air wind generator, a new main
and a jib designed to withstand the constant high winds of the Southern Ocean,
and we were set to go.I had 2 SSB
receivers, a satellite phone, an email set up, and 4 handheld GPS�s, a sextant
on board.
II took all the abuse of 17,000
miles of gales, knockdowns, floodings and violent days and nights on my way to
New Zealand.When I would get greedy
for speed on those great running reach days, I would start to hear the upper
deck under the mast creak.We never
averaged more than 5kn and later even slower as I got closer to NZ.That was one more refit needing to be
done.
Before I left NZ, I tore the deck
apart and rebuilt under the mast step with teak and thickened epoxy.The last of the deck fittings that could
have wet core were dug out.I even
pulled off the decrative teak and the hand rails to fill in the screw areas
with epoxy. By this time there were issues with the plywood bulkheads
delaminating so they were rebuilt.And
last but not least, on the final shake down sail back up the east coast of NZ,
we found that the bow cap had split from the hull. In fact I suspected that this
was not new and the hidden leaking that had been dogging my attempts at dry
lockers for most of my days with II.Instead of leaving on Nov 11th, 2006, I was pulling the bow
sprit off and rebuilding the bow.I
averaged a full knot + faster on the legs from NZ to the Carib as the deck
never creaked once.
So all in all, there is no piece of
hull on II that has not been rebuilt, but I dare say there is no other sailboat
more solid and seaworthy.The interior
and cosmetics have sorely been neglected to structural work.Yet, she sails like a dream, to wind and
with following seas, to 60� seas and day after day for 5 � months at a time,
cold and wet.In the last crossing north
from the Carib to RI we took our only roll, going half way over and back up. I was hand steering and spent that incredibly
long 10 seconds underwater, tethered, bracing myself with the dodger
frame.But the rig held.The structure of the boat was true.
I have had inquiring emails from
other smaller boat owners, other SC owners and I dare say, I would hate to
think that my successful rounding would be misleading regarding the preparation
and need for alterations in such a boat carrying a skipper with big
dreams.Homework.Gotta do your homework.I may have not doted so much on the
electronics and gizmos, and she isn�t a craftsman�s masterpiece, but she is
solid as a rock and a fine Little Sailing Ship.
Fairest
of Winds and Love
Captain Donna Lange and SV_Inspired Insanity
(Ps. My apologies that there is not a photo or video journal of this refit. I have never been a camera guru but I will be taking some photos after the fact where possible soon. Thanks)