We build back up the interior of sailboat Rossa, a 1979 Bayliner Buccaneer 335, which was abandoned in San Francisco until we sailed her down the Pacific Coa...

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in the last sailor rama video we sailed

across the Tejano PEC arrived at the

southernmost port of mexico and began

the demolition of the interior of silva

rosa we started this interior remodeling

by ripping out the wood and fiberglass

in the saloon galley and engine

compartment we've taken everything out

she's almost completely empty

we made time for a little taste of

chiapas chocolate finally the engine

came out and the masts came down so that

we could work on the compression post

and the mast step I cleaned up the

MassDEP area and prepared it to

reinstall the aluminum plate however

under the corrosion I found after a

little sanding that the aluminum plate

was cracked warped and generally beyond

saving

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g10 is a material created by layering

fiberglass and epoxy and curing it under

extreme pressure we have been carrying

around some thick offcuts of g10 for

some time and now it seemed like the

perfect use as a new mask step and base

to avoid the stainless steel / aluminum

corrosion problems in the future

two blocks are in the hole

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we need a popsicle stick around here we

like the friendly jumping spiders and

not so much the ominous webs of the

black widows setting up shop under the

boat meanwhile the industrious

leafcutter ants helped us to keep our

lunch area clean while slogging away at

their own impossible tasks preparing

Rosa for the next sailor we also wanted

to address the issue of the clogged up

cockpit drains or scuppers we would

close the old holes up and make some new

wider more direct ones we decided that

this would involve fabricating a tube

very similar to the rudder post tube

that we constructed the last time Rosa

was out of the water

we found a discarded PVC pipe and sanded

it down lightly so that the fiberglass

would adhere to it properly the key to

this creation would be to make a tight

wrap with zero air bubbles which is why

we rubbed the shaft persistently while

rolling and our neighbor came by to

observe and lend a helping hand

voila we cut it in half and trimmed it

to size for the two sides it required

some cutting and coaxing and sanding to

fit the tube smoothly

we also touched up and fared the area on

the rudder which we had previously

sanded down to accommodate the old

awkward drains still the yard dog his

name means mast back inside the boat

there were tons of old holes from

electrical wiring that I filled in with

thickened epoxy and now needed to be

smooth and sanded the original gel coat

would not necessarily have to be removed

completely in a lot of places but it

wouldn't need to be wire brush to help

the new paint adhere to it our trimaran

neighbors were also working away on

their boat and they had been here almost

a year they had just finished up

spray-painting the exterior and they

would be soon remodeling the interior as

well check out sailing less plastic for

their story

the demolition was complete and the time

had finally come to begin erecting the

new interior we traced some of the old

wood pieces directly while other

surfaces would have to be carefully

measured and reshaped

get a mosquito hanging out of his mouth

we wanted the new benches and shelves to

be super simple without drawers or

components that can wear out or require

miscellaneous metal parts like hinges or

latches which would be difficult to

acquire here anyways just simple cubby

holes to start out the local welder shop

made a slick new bottom for the

compression post and we screwed it into

the new g10 base finally the deck looked

properly convex instead of concave and

the MassDEP was also now quite secure we

experimented with using some auto body

filler which is a two-part thickened

polyester resin to smooth out some areas

needing some flattening and to create

full 'its wherever the verticals and

horizontals meet

however we decided pretty quickly that

it could only be trusted in

non-structural spots compared to the

West system epoxy polyester just is very

weak we created some homemade tools

including a compass for transferring

whole angles to the plywood how the

mosquitos going at this point with the

heat and the bugs the whole task was

starting to feel very self flagellation

what were we doing remodeling a boat

that we would not get to enjoy the

fruits of labour of the floor or a cabin

sole was very tricky to reshape and

epoxy down however the saloon berths and

benches assembled quickly first we

addressed the verticals

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and then the horizontal supports

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the primitive compass came in handy for

getting all those odd angles and the odd

angles of the sailboat interior required

us to leave some extra centimetres for

shaving and snipping when fitting the

final pieces

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we made the initial cut for the storage

bins with the multi-tool and opened them

up after with the jigsaw

again we wanted to avoid stainless steel

hinges and latches and things of that

sort

being in an isolated part of the world

where marine hardware is not easy to

find the plywood was also not optimal

around here so we would have to prepare

and coat it with generous amounts of

epoxy I sanded to prep the surface so

that the coatings would adhere to it

properly cleaned with alcohol because we

couldn't find acetone anywhere nearby

and then I only made one small batch of

epoxy at a time because it set up

quickly in this hot environment the soft

squeegee worked well to spread the epoxy

evenly and quickly

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we use thickened epoxy to create

Phillips and all the angles and corners

for smooth transitions and no cracks for

small items or dampness to get stuck

inside at the same time that the beds

and bins we're coming together we also

started working on some new shelving and

storage that would hold items much more

securely the shape of the beam of the

boat presented some woodworking

challenges it was a matter of cutting

shapes and trimming them down to fit the

angles properly

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we acquired sailing less plastics old

fuel tank doubling roses diesel capacity

the tank would require a cradle in the

crawl space under the cockpit

this was also a challenging design

requiring a fair bit of shaping

problem-solving and trimming as you go

all the while I was prepping surfaces

for the new fiberglass epoxy and paint

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we also began to build the new galley

and engine compartment there was hardly

any bulkhead support in the engine area

originally which was something we wanted

to bolster up as well another fun

creature that we found living among the

stored items under the boat each

afternoon the rain clouds would blow in

from the mountains and either give us a

nice lightning show or pass over us with

a bit of rain today was another mast day

this time our neighbors penny and Bill's

masts was going up Robby offered to tie

the lines in such a way that they could

be self released when the task was done

with the crane

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because things go

the method worked perfectly so that no

one would have to climb up the mast

afterwards to release any ropes however

the force day we figured out would have

to be lengthened at some point if the

masts were to have a proper rake in any

case another successful mass standing

back up

would work assembly was almost coming to

an end as we puzzle piece then screwed

together the galley area now it was all

about trimming off those extra bits

smoothening out everything with

thickened epoxy and making those Philips

and joints

all this galley space was originally

inaccessible and lacking shelving

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the bottomless crevice where things

would disappear into was now a useful

fuel tank area in the last two weeks of

this project we were in a special state

of mind getting a little loopy without

having a kitchen to cook in there is

very little video evidence of me

painting the entire wood fiberglass and

epoxy job with the surgical glossy white

we used the same local heavy-duty Comex

one part paint that we use to paint the

anchor locker some months before seeing

as the anchor Locker was probably a best

test of durability of paint it had held

up pretty well the idea was to leave the

new captain of Rosa with a blank canvas

on which he could create whatever he

pleased

we knew that still a lot of work

remained but that is the nature of an

old boat all throughout this project I

kept a fairly meticulous account of all

the costs marina costs our hotel costs

nuts and bolts wood and fiberglass just

to give you a rough idea not including

the cost of the engine overhaul which

would go on for quite some time after we

departed we came in right on our

estimated budget of 3500 we also had a

four gallon jug of West's system on

board which we carried with us from the

states which helped bring down the price

of good quality epoxy for this project

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and with such a tight timeline on budget

we were quite pleased with the results

nothing fancy but a whole lot more easy

and comfortable we hope Cheers

here's to making unused boats saleable

livable and getting them out on the

water again

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