Do-it-yourself Boatyards

Galesville Harbor Yacht Yard off Chesapeake Bay is one of the dwindling number of boatyards that allow boat owners to do all or some of their haulout work on their own. Liability issues have prompted many yards to require boat owners to secure their own scaffolding for use. This is something to check for if you plan on power-buffing your hull.

DIY yards are critical to affordable boating, but they are a dying breed. he cost of buying, owning, and mooring rather than in a costly marina, their local governments to draft wa- Tmaintaining a has spi- and find a boatyard that’s user friendly terfront redevelopment plans that are raled to an all-time high. The ranks to the “do-it-yourselfer.” sensitive to boatyards and other “wa- of entry-level sailors, starting out in Across the country, this third step ter dependent” operations like marinas smaller boats, are thinning, and if both is becoming less of an option. Do-it- and sailing clubs. It pays off when boat- the industry and the consumer aren’t yourself boatyards are an endangered ers make themselves heard at planning careful, mid-sized keelboat sailing will species, and those of us who use them and zoning hearings. When a boatyard once again become an activity relegated need to become more proactive about succumbs to real-estate pressure and is to those of means. ensuring their survival. replaced by shops selling plastic oysters, Just stroll through any boat show and As boat owners contend with more T-shirts, and ice cream cones, the local hear how easily six-digit boat prices roll and more boatyard restrictions on what recreational boater is the biggest loser. off the tongues of today’s production- projects an owner can do, yard own- boat dealers. Such pricing was pioneered ers are facing pricing pressures that are The business side by Hinckley, Morris Yachts, Swan, and exacerbated by escalating taxes, labor It’s important to keep in mind that other high-end builders, but now it’s costs, and insurance premiums. These boatyards are a for-profit business and trickled down to more mainstream sail- hardships have caused many a yard a nautical rendition of fair trade should boats at the same time marina slip fees, owner to throw in the towel and sell include good service for a reasonable boatyard labor rates, insurance prices, off to developers who have no intention fee. It’s not unreasonable to expect the Photos by Ralph Naranjo Ralph by Photos and the cost of a quart of varnish have of recapitalizing a boatyard—or even yard’s staff to have a well-maintained gone through the roof. using the property in a “water depen- Travelift, Brownell trailer, railway, or For many sailors, survival at sea has dent” context. crane to haul your boat. The operator become a cash flow issue rather than a This restructure of the waterfront should be skilled and by reflex should be test of seamanship, and through do-it- to non-water-dependent use is a land able to get the slings properly positioned yourself efforts, they have managed to management failure that is happening and your boat safely blocked. keep the dream alive. There’s a three- in most every coastal community across However, if you deliver the boat with fold approach to cost-effective boating: the nation. Boat owners—particularly a rolled up on a headsail furling Buy a sound but older boat, keep it on a those of the DIY variety—should urge system, don’t be surprised if you’re

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we are, and it’s definitely the kind of operation where the staff makes a sailor feel at home. This sense of compatibil- ity between a yard and a boat owner is important, especially if you like to work on your boat. There’s tangible value in having an enjoyable place to add the TLC your boat deserves, particularly when you’re likely to be spending a fair amount of time there. The trend toward establishing boat- yards on the least desirable parcels of land has caught on, and many are packed like a sardine and smell worse thanks to adjacent sewage-treatment facilities. Finding a nice place to work, with friendly folks to share a break with, is a luxury indeed. A skilled Travelift operator, like this one at Galesville boatyard (above), will be able What to look for to instinctively arrange rigging and place the slings, no matter the hull shape. Every skipper should go through a “what-if” scenario when considering a charged extra for its removal. In fact, age it—but whatever the case, owners specific place to haul. These “what-ifs” how a boat owner and their boatyard that attempt to fly under the radar with include the potential impact of gale or of choice treat a furled headsail says a owner-hired, incognito subcontractors storm-force winds, a significant tidal lot about all involved. Insurance claims have led many yards to clamp down on rise, and torrential rain. show that a significant amount of ves- the DIY option and mandate that all Low-lying facilities exposed to the sel damage has been caused by partially work is handled through the yard. most volatile wind direction can spell unfurled headsails capsizing blocked- The win-win strategy that will help trouble, as can a yard that’s notorious up . All it takes is a volatile maintain boat owners’ ability to do their for catching rain water runoff that turns summer thunderstorm to lay waste to own work is developing a good work- a hard pan surface into soupy muck— a vessel hauled with a furling headsail ing relationship with the yard staff. The destabilizing the jack-stands that sup- tied off to an upper shroud. In short, guy who comes into the shop asking port the blocked up boats. competent boat storage is a two-way to use tools and wondering where the Our sample yard, Galesville Harbor street with both the owner and the “scrap” teak and stainless steel are kept Yacht Yard is nestled in an estuary pro- boatyard steering the outcome. does little to evoke a favored customer tected from the Chesapeake Bay as well Before hauling, make sure all the relationship. The DIYer who hires the as the ocean. During Hurricane Isabel cards are on the table. Most yards have yard to handle repairs and installations in 2003, tidal rise presented the biggest an information sheet, perhaps even a beyond his own skill and ability and de- concern there, but it was the vessels in website, that lists the yard’s do’s and velops a friendly relationship with the the marina rather than those blocked up don’ts, and spells out the scope of work crew becomes a goodwill ambassador on land that suffered most. In other parts that an owner can do on his own. Be for all self-reliant sailors. of the bay, more-exposed boatyards suf- sure to learn the rules regarding sub- fered from the extreme tide and the de- contracted work, a gray area that can Picking the right boatyard bris that swept through the hauled-out cause serious dissension between yard We looked for a good example of a small fleet, toppling jack-stands and the boats staff and a boat owner. boatyard operation that was representa- on them. Volatile winter storms can pack Boatyards are in the business of sell- tive of yards around the country and the punch of a tropical storm, so whether ing labor, and their profitability revolves set out to field test a simple boatyard afloat or on dry land, a vessel needs to be around keeping craftsmen busy. A yard ranking system, one that you can use to able to endure the onslaught. that’s willing to allow boat owners to do evaluate the facilities in your own back- their own work is in some ways con- yard. (See “Reader Survey,” page 10.) equipment & operator skill stricting its profitability, and the owner Galesville Harbor Yacht Yard on Frayed lifting slings, deteriorated pil- who tries to sneak in a subcontractor is Maryland’s western shore of Chesa- ings, and rusty machinery may still “biting the hand that feeds.” Most yards peake Bay is more casual than corpo- work, but more often than not, they are have a service charge that applies to sub- rate. There’s a feeling that the owner and signs of the overall quality of workman- contracted work—some even encour- manager are as caught up in boating as ship that a boatyard has to offer. Those

 june 2009 www.practical-sailor.com s p e c i a l r e p o r t seeking lowest-cost options need to be especially aware of how their boat will be hauled and handled. When all is said and done, it’s hard to beat a new or well-maintained Travelift or hydraulic trailer. Equally important is the dock or ramp it operates on. But no matter how good the gear, the skill of the operator is the most important variable of all. With sailboats, sling placement is crucial, and the geometry of the hull shape in conjunction with the cable lead adjustability on the lift will determine how equal the sling loading will be. Also critical is the cable angle, a factor that can lead to sling slippage, and in extreme cases, a vessel being dropped. A skilled operator will know how to handle various hull shapes and what Once a boat has been shored and blocked, it’s a good idea to layer tarps or plastic rigging must be undone to fit a vessel sheeting beneath it. That keeps cleaners, paint, paint removers, and other chemi- into the confines of a Travelift’s web. cals from contaminating the ground. Layering the tarps means you can remove a One bit of boatyard wisdom worth soiled one and have a clean surface to kneel or stand on. remembering: “Being told that yours is the biggest vessel ever hauled by the facility should not be confused with set, he hauled the boat stern first. This cradles that spread loads to numerous words of encouragement.” was easier than removing a headstay large contact points and allow the Cranes up the ante for concern, and and inner forestay, and allowed for bet- to hang. their operation requires extreme care, ter sling spacing. The efficient haul was In gale-force conditions, some race especially if they are used to transport followed by a thorough high-pressure boats stowed in such a fashion, espe- a vessel once it is hoisted from the wa- washdown that removed all soft marine cially those stored with their masts still ter. Bulkhead collapse, tire failure, and growth, leaving behind only a few tena- stepped, have been known to develop changing ground angles can set the stage cious barnacles at the bottom. a pendulum-like keel motion that can for disaster. Hauling via a Travelift, hy- capsize the cradle-supported boat. draulic trailer, and even the venerable Blocking and shoring Wedging the keel bulb to prevent such marine railway are usually better op- Standing up a vessel that’s de- tions. Above all, if your boat is being signed to float can be quite a chal- hauled by a crane, be sure the operator lenge. In many cases, the hull skin uses “spreader bars,” a cage that keeps the is too thin to take the heavy point sling load from compressing the hull. loading associated with too few The crew from Galesville favors a blocks under a keel or near over- conventional Travelift that runs out extended pads or jack stands. onto a well-supported lift pier. Their Properly executed, the block- setup is well protected from wind and ing and shoring process is a means sea. Eddie, the consummate lift opera- of spreading contact loads and tor, with decades of experience, knows rigidly supporting a vessel in a both the capacity of his lift and the chal- vertical position. Sailboats with lenges of any given vessel. external ballast easily endure the When it came time to haul PS test boat pressure imposed by keel blocks Wind Shadow (an Ericson 41 ), Ed- but may be troubled by the hull die had owner and PS Technical Editor weight pressing down and flexing Ralph Naranjo turn the boat around, the keel/hull joint. Many lightly release the back stay, and with runners built race boats are fitted to special

Many DIY yards will let boat owners rent or borrow specialized tools like prop pullers or oversized wrenches. practical sailor june 2009  reader survey reader survey

Rate Your Favorite DIY Yard in PS’s Online Survey

n Practical Sailor’s ongoing effort to keep cruising afford- boat hauled there several times and always went away happy Iable to everyone, we’re conducting a survey to identify and full of admiration for their talent and character. — Bruce outstanding do-it-yourself boatyards across the U.S. We be- Sinclair; Pretty Penny; Vallejo Yacht Club, Vallejo, Calif. gan with a sample boatyard, Galesville Harbor Yacht Yard in Maryland, and developed a simple rating system to allow Jensen’s Shipyard, San Juan Islands, Wash. — Jensen’s readers to grade their own DIY yard. (See Galesville’s report Shipyard in Friday Harbor is a great place to work on your own card on the facing page.) boat. — G. Booth, via e-mail We’ve already heard from some readers about their favor- ite DIY boatyard—check out the reader-recommended yards Schroeder Yacht Systems, Deltaville, Va. — This DIY yard listed below. But if we’ve missed your top pick or you’ve yet staffs friendly, congenial people, who do very competent to fill out the survey, let us hear from you. Visitwww.practical- work. Their labor charges are reasonable, and monthly stor- sailor.com and take the reader survey about your DIY haulout age is inexpensive. — Jack Berkey, via e-mail haven. Bob Walton’s boatyard, Delta Marina, Rio Vista, Calif. Reader picks: — This yard’s prices are low, and their willingness to help is Berkeley Marine Center, Berkeley, Calif. — This yard al- astounding. This boatyard is within a day’s cruise of San Fran- lows and encourages do-it-yourselfers to handle their work, cisco (50 nautical miles from Bay Bridge) and is a little-known but the knowledgeable and friendly staff headed by Cree Par- bargain in a high-priced region. — Larry Smith; S/V Pleamar, tridge and Karl, his yard manager, are available for consultation 1983 Aloha 32; Vallejo, Calif. or pulling the proverbial horse out of the ditch when you have bitten off more than you can chew. —John T. Sutton; Toronto, Seal Cove Boatyard, Cape Rosier, Maine — These guys are Ontario pros, willing to assist and help with the smallest problem— real or imagined. — Aaron Glazer; Adagio, Albin 27 trawler; Dutch Wharf Boatyard, Branford, Conn. — This moder- Cape Rosier, Maine ate-sized, family-owned yard specializes in wooden boats but is absolutely competent in all things mechanical, electrical, and Catawba Moorings, Port Clinton, Ohio — Bob James, via fiberglass. Dutch Wharf also has an exceptional paint shop. I e-mail have used this yard for over 30 years and highly recommend it, its people, and its quality. — James M. Malkin; New York City, N.Y. Knight & Carver, National City, Calif. — I’ve been taking my boat here every three years for bottom paint. The yard Napa Valley Marina, Napa, Calif. — Located up the Napa caters to megayachts, but smaller-boat sailors like us are wel- River from San Francisco and San Pablo bays, this marina is a come, too. The people are most professional and helpful, never friendly, family-owned place. Very helpful people, complete measuring you by the length and value of your boat. — Jack facilities, and the ability to haul any kind of boat. I’ve had my Grenard; Islander 36; San Diego, Calif.

an oscillation makes sense. it diverges, the more there’s a tendency doing himself. Despite good intentions The GHYY yard crew used plenty of to “kick out” a stand if the vessel starts and prearrangements, most refits, even timber blocks for keel support and cross oscillating in high winds. Chaining the modest ones, lead to new discoveries chained screw-jack poppets to provide stands together lessens this likelihood. and more work. Seldom does one find both athwartship and fore and aft stabil- less to fix than originally planned. This ity for Wind Shadow. Services is where the DIYer can make or break There is a subtle but significant differ- Once your boat is high and dry, a last a relationship with a boatyard and the ence between these three-legged stands. check should be made to reduce wind- art of spending refit dollars efficiently The ones with a narrower base are less age, and the rigging that was loosened is truly tested. stable and harder to use effectively. or disconnected for hauling should be By noting in advance the skills of the When supporting a sailboat with tripod reattached. Then it’s time to get on with craftsmen in the boatyard, you know like jack-stands, the idea is to extend an the maintenance routine. whether or not appropriate expertise imaginary right-angle line from the hull Well ahead of time a boat owner is available. However, fitting in more skin to the ground at every pad point, should work out with the yard man- work can be a problem, especially dur- and make the jack-stand’s centerline ager what projects he wants the staff ing the spring rush. That’s why sched- axis coincide with this line. The more to shoulder and which ones he will be uling a haulout date after the fleet has

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PS Technical Editor Ralph Naranjo rated Galesville Harbor Yacht Yard in Maryland after a recent haulout of his Ericson 41 Report Card sloop and PS test boat, Wind Shadow. Name: Galesville Harbor Yacht Yard Criteria Grade Comments All-weather Pleasure Cove Marina, Pasadena, Md. — Pleasure Cove is protection A Nearly landlocked located on protected Main Creek off Chesapeake Bay at the Hauling mouth of the Patapsco River. Baltimore is close by, and An- equipment B Older but functional Travelift napolis is a nice half-day’s sail away. This yard is also one of a Operator skill A True veteran few on the Chesapeake that can haul wide boats. They have mechanics, a parts store, a fuel dock, and a very friendly staff. Blocking B Some narrow-based poppets Ask for Don. — Jess Berndt, via e-mail DIY restrictions A Minimal (no DIY spray painting)

Swantown Marina and Boatyard, Olympia, Wash. — Shop capability A Machining, welding, paint spraying Swantown will let you do your own work, and they have all the amenities (air, electricity, disposal facilities), and some pretty Office A Efficient, small operation good contractors for when your job gets too big or too techni- Security A Low-risk residential area cal. — George Lukacs; 31-foot Hallberg-Rassy Ambiance A Small yacht harbor, friendly locals Nelson’s Boatyard, Bon Secour, Ala. — This yard is lo- cated on the southeast corner of Mobile Bay, about ¾-mile off the Intracoastal Waterway. The depths are good. It’s a small Frank Hall Boatyard, Westerly, R.I. — An excellent family- yard with tons of experience. The Nelsons have been here for run boatyard on the Pawcatuck River. We’ve been customers generations. I’ve often thought that snowbirds should store since 1991. This yard has made keeping our boat possible, as their boats at Nelson’s and fly home out of Pensacola, Fla., or we did everything we could ourselves. It also has high-quality Mobile, Ala. — Bob McDonald; Windy City, Island Packet 35; services in all areas. — Rick Gleason; Nell, 1981 Bristol 32 Gulf Shores, Ala. Cove Springs Marina, Green Cove Springs, Fla. — This Mattapoisett Boatyard, Buzzard’s Bay, Mass. — This is a is a yard that any DIY boater would love. They have very fair wonderful yard, very friendly and helpful employees, and they rates, can lift most boats, and put them on the hard without encourage DIY work. They have installed numerous electrical mast removal. You can stay on your boat while it is on the outlets and water nozzles around the yard for this purpose. hard, and they have showers and restrooms. — Sandbagg’n David Kaiser, the general manager, is very knowledgeable Sam, via e-mail and very willing to provide all types of information to help you do the job. Lastly, they have a well-stocked parts depart- Sailing Associates Inc., Georgetown, Md. — This DIY yard ment that’s been a life saver. — Rick McCowan; S/V Breezes; is on the Sassafras River, which flows into the upper Chesa- Mattapoisett, Mass. peake Bay. — Sidney Axinn, via e-mail

been launched makes good sense. Also a casual chat are least appreciated. The Unfortunately, escalating costs are keep in mind that pestering a pro is—in dividing line between a friendly conver- causing many to seek additional profit a boatyard context—being a very “bad sation and an unwelcome distraction is centers, and hiring a staff to handle neighbor,” and just like asking where ill defined, but when DIYers are viewed mechanical, electrical, and paint work the “grab-bag” of scrap teak is kept, by the yard staff as an annoyance, it isn’t requires significant labor sales in order overbearing persistence hurts all do-it- long before the yard transitions into a to offset the costs. Eliminating owner- yourselfers in the long run. “no owner work allowed” facility. Some- done maintenance may initially keep thing to keep in mind when you seek out technicians busier, but in the long run, The heart of the yard a work break in the AC. many clients will look for alternate As with any business, the office is the On the other hand, the haul, store, yards. central nervous system of a boatyard, a and launch service holds the highest Working with boatyards that allow place where work orders are developed, profit margin in the boatyard business, the do-it-yourselfer to thrive is a two- time cards tallied, and bills are spawned. and quite a few smaller yards still hold way street, and sailors need to do their It’s also where the “time is money” rule to a business plan featuring a small staff part by making sure these boatyards prevails, and during busy periods, dis- and a willingness to allow owner-done remain a part of the ever-changing tractions from boat owners looking for maintenance. waterfront.

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