This is the reality of a professional-level refit: the long, meticulous, and often messy work that happens before the paint goes on. There's no glory in fairing, but it's what separates a quality finish from a amateur one. In this Paikea refit update, we're deep in the "unsexy" phase: prepping the entire port-side interior for paint. This means endless sanding, filling old penetrations, and—as always—uncovering and fixing unexpected problems, like a major leak in a cockpit locker. Join us as we tackle the essential but unseen work that transforms a structural shell into a finished, seaworthy interior. CHAPTERS: 00:00 The "Unsexy" Reality of Boat Refits 00:45 Touring the Port Hull Progress 02:15 Installing Flush Hatches & 3D-Printed Drains 04:10 The Systematic Sanding & Fairing Process 06:30 Widening Doorways & Composite Edge Capping 08:15 The Weight Reduction Spreadsheet: 650kg Lighter 09:50 Discovering a Hidden Hole & Rotten Core 12:40 The "Easy" Solution vs. The "Hard" Solution 14:25 Laminating the Repair 15:00 The Final Push for Paint Prep SAFETY DISCLAIMER: PROFESSIONAL WORK This video documents professional marine work with significant risk of injury or vessel damage. This is NOT DIY instruction. You are solely responsible for your own safety and actions. We are not liable for any application of this information. Full Disclaimer: https://youngbarnacles.com/website-disclaimer/ USEFUL LINKS ➜ Supporting blog post https://youngbarnacles.com/unglamorous-boatwork-fairing-fixing-leaks/ ➜ Want to go deeper? Access our detailed composites videos, project files, and community on the Youngbarnacles Members Hub: https://youngbarnacles.com/plans/all-access-memberships/ ➜ Need world-class engineering for your project? Learn more about our professional design and consultancy services at SYAS Performance: https://syasperformance.weebly.com/ ➜ Free Sailing Library: Check out our free guides on composites, systems, and seamanship: https://www.youngbarnacles.com/resources MUSIC YouTube Audio Library ➜ https://www.youtube.com/

We're hitting a major milestone in the Paikea refit: installing the composite flush hatches and painting the inside. But this video is about more than just finishing work. We'll show you the tangible results of our weight-saving mission—we've already removed 650kg, putting us well on our way to our goal of shedding a full ton. In this update, you'll see: • The final installation of our custom-designed composite hatches. • The 3D-printed drainage systems that make them work. • The extensive prep and painting of the hull sides. • The interior progress, including new composite bulkheads and structure. CHAPTERS: 00:00 Hull Weight & Waterline Progress 01:15 The Goal: Removing a Ton of Weight 02:45 Interior Refit & Composite Structure Update 05:25 Carbon Fibre Hardtop Finishing 06:00 Foredeck & Fuel Locker Prep 06:30 Installed Composite Hatches & Drainage 08:15 Final Pre-Paint Prep & Fairing 09:45 Painting the Hull Sides 11:45 Explaining Hatch Drainage Systems SAFETY DISCLAIMER: PROFESSIONAL WORK This video documents professional marine work with significant risk of injury or vessel damage. This is NOT DIY instruction. You are solely responsible for your own safety and actions. We are not liable for any application of this information. Full Disclaimer: https://youngbarnacles.com/website-disclaimer/ USEFUL LINKS ➜ Supporting blog post https://youngbarnacles.com/paikea-refit-weight-reduction/ ➜ Want to go deeper? Access our detailed composites videos, project files, and community on the Youngbarnacles Members Hub: https://youngbarnacles.com/plans/all-access-memberships/ ➜ Need world-class engineering for your project? Learn more about our professional design and consultancy services at SYAS Performance: https://syasperformance.weebly.com/ ➜ Free Sailing Library: Check out our free guides on composites, systems, and seamanship: https://www.youngbarnacles.com/resources MUSIC YouTube Audio Library ➜ https://www.youtube.com/

This video documents two key upgrades in the Paikea refit: the professional installation of custom deck hatches and the complete replacement of leaky portlights on our Catana 42 catamaran. In the first half, see the process of fitting and aligning a new composite deck hatch, focusing on the use of 3D-printed jigs for perfect hinge placement. The second half covers the engineering behind converting failed, inward-opening portlights into outward-opening hatches with integrated gutter drainage. The focus is on professional methodology, from solving deck curvature challenges to implementing permanent, watertight solutions. CHAPTERS: 0:00 Introduction: Fitting Composite Hatch Rim 1:00 Deck Hatch: Cutting the Deck & Fitting the Frame 4:10 Using 3D-Printed Jigs for Precision Hinge Alignment 6:45 Drilling Hinge Holes with Custom Fixtures 11:30 Portlight Replacement: Removing Old Units & Cutting New Openings 13:00 The New Hatch Design: Integrated Gutter & Drainage 16:45 Final Installation of Side Hatches 19:30 Detailing: 3D-Printed Drain Fittings SAFETY DISCLAIMER: PROFESSIONAL WORK This video documents professional marine work with significant risk of injury or vessel damage. This is NOT DIY instruction. You are solely responsible for your own safety and actions. We are not liable for any application of this information. Full Disclaimer: https://youngbarnacles.com/website-disclaimer/ USEFUL LINKS ➜ Supporting blog post https://youngbarnacles.com/professional-boat-hatch-installation/ ➜ Want to go deeper? Access our detailed composites videos, project files, and community on the Youngbarnacles Members Hub: https://youngbarnacles.com/plans/all-access-memberships/ ➜ Need world-class engineering for your project? Learn more about our professional design and consultancy services at SYAS Performance: https://syasperformance.weebly.com/ ➜ Free Sailing Library: Check out our free guides on composites, systems, and seamanship: https://www.youngbarnacles.com/resources MUSIC YouTube Audio Library ➜ https://www.youtube.com/

This video shows the complete process of building our composite hatches, from the 3D printed custom molds to the final lamination. We demonstrate how we created two separate 3D printed molds—one for the hatch lid and one for the gutter/frame—and walk through the entire build sequence: mold preparation, gel coating, fiberglass lamination, and post-processing. This method provides a practical solution for creating strong, complex composite parts with precise geometry without expensive tooling. CHAPTERS: 0:00 Introduction: Hatch Lid & Frame Molds 1:30 Designing & Printing the Modular Molds 4:15 Mold Prep: Wax, Plasticine, and Sealing 8:05 Applying Gel Coat as a Primer Layer 11:20 Fiberglass Lamination Setup 14:50 Demolding the Hatch Lid and Frame 18:25 Post-Processing & Trimming the Parts 22:00 Dry-Fit Assembly & Next Steps SAFETY DISCLAIMER: PROFESSIONAL WORK This video documents professional marine work with significant risk of injury or vessel damage. This is NOT DIY instruction. You are solely responsible for your own safety and actions. We are not liable for any application of this information. Full Disclaimer: https://youngbarnacles.com/website-disclaimer/ USEFUL LINKS ➜ Supporting blog post https://youngbarnacles.com/composite-hatch-build/ ➜ Want to go deeper? Access our detailed composites videos, project files, and community on the Youngbarnacles Members Hub: https://youngbarnacles.com/plans/all-access-memberships/ ➜ Need world-class engineering for your project? Learn more about our professional design and consultancy services at SYAS Performance: https://syasperformance.weebly.com/ ➜ Free Sailing Library: Check out our free guides on composites, systems, and seamanship: https://www.youngbarnacles.com/resources MUSIC YouTube Audio Library ➜ https://www.youtube.com/

After 32 years, Paikea's original deck hatches were leaking, heavy, and difficult to service. Rather than opting for an off-the-shelf solution with its own compromises, we engineered a complete composite hatch system from scratch. This video details the design philosophy and engineering behind our new hatches, covering: The analysis of why commercial hatches failed to meet our specific needs for offshore sailing. The critical design elements: flush mounting, integrated gutters, and a structural rim that reinforces the deck. The development of custom 3D-printed nylon-carbon friction hinges for ultimate serviceability. How a circular lens reduces weight and heat gain while maintaining strength. The final result: a hatch system that is half the weight of the original, fully flush, and designed to meet ISO/ABS standards. This is applied marine engineering for a real-world refit problem. CHAPTERS: 0:00 - The Problem with Original Hatches 2:15 - Why Commercial Hatches Weren't the Solution 5:30 - The Design Brief: Waterproof, Flush, Serviceable 8:10 - The Structural Rim & Deck Reinforcement 11:25 - Seal Geometry & Gutter Design Explained 14:40 - Custom 3D-Printed Friction Hinges 18:15 - The Lid: Safety, Weight, and Lens Rationale 22:00 - Prototyping & 3D-Printed Molds 25:30 - The Final Weight: 3kg vs 5.7kg (Original) USEFUL LINKS ➜ Supporting blog post https://youngbarnacles.com/engineering-composite-flush-hatches/ ➜ Want to go deeper? Access our detailed composites videos, project files, and community on the Youngbarnacles Members Hub: https://www.youngbarnacles.com ➜ Need world-class engineering for your project? Learn more about our professional design and consultancy services at SYAS Performance: https://syasperformance.weebly.com/ ➜ Free Sailing Library: Check out our free guides on composites, systems, and seamanship: https://www.youngbarnacles.com/resources MUSIC YouTube Audio Library ➜ https://www.youtube.com/

We're tackling one of the biggest challenges of living on a boat: creating functional storage without adding weight. In this episode, we design, build, and install a custom composite shelf and cupboard unit in our sailboat's cabin. You'll see the entire process, from the initial challenge of "eyeballing" the fit in a space with countless angles, to cutting composite panels with the right blades, and the time-saving trick of pre-painting components before installation. We focus on making it as strong and lightweight as possible, with the final primed shelf weighing just 1.55kg! What you'll learn in this video: The challenge of making things look right vs. being technically right on a boat. How to choose the right jigsaw blades for cutting carbon fibre and composite panels. Our method for gluing and assembling composite parts on the bench. Why we prime and paint before installing components in tight spaces. Using peel ply for a perfect finish on fibreglass tape. This custom shelf adds crucial storage for books and gear, integrates into the boat's structure, and proves that you don't have to sacrifice function for performance. YouTube Video Chapters 00:00 - 01:00: Introduction: Maximizing Space on a Boat The host introduces the episode's goal: to show the design and construction of lightweight, strong cupboards and shelves. 01:00 - 04:16: The Challenge of "Eyeballing" in a Boat Fitting the shelf in a space with many conflicting angles and slopes. The importance of making it look right, not just be technically correct. 04:16 - 06:06: Cutting Composite Panels: Tools & Blades A discussion on the best tools and jigsaw blades for cutting carbon fibre and composite materials without damaging them. 06:06 - 07:14: First Fit Check and Scribing Checking the first cut, dealing with gaps, and explaining how composites allow for filling and fixing imperfections. 07:14 - 11:14: Gluing, Assembling, and Pre-Painting Assembling the shelf unit on the bench and the clever step of priming it before installation to save time. 11:14 - 13:13: The Weight & Pre-Painting Advantage Weighing the finished shelf (1.55kg) and explaining the benefits of pre-painting hard-to-reach areas. 13:13 - 15:04: Final Glue-In and Taping The shelf is glued into place. Using peel ply on the tape for a smooth, easy-to-finish surface. 15:04 - 16:43: Fairing, Sanding, and Final Thoughts The final stages of fairing and sanding. Recap of the benefits: functional, lightweight, custom storage. 16:43 - 18:49: Project Wrap-Up & Teaser for Next Week The finished painted shelf. A teaser for the next video topic: designing and building custom composite hatches to solve water leakage issues. Teaser for Next Video: We're solving a major issue on board next time: keeping the wet stuff out! We'll dive into the design and build of our own custom composite hatches. What's with the mysterious hole in the middle? You'll have to wait and see! Youngbarnacles Membership: Go beyond YouTube. Get detailed tutorials and a community for serious learners. www.youngbarnacles.com SYAS Performance: Our professional design & engineering consultancy for advanced composites, hydrofoils, and owner's representation. https://syasperformance.weebly.com/ Music from https://www.youtube.com/

Can you fix an imploded part post infusion? Watch this week as we show you how we went about saving our infused and imploded box beam from the rubbish bin. Shayne is back to show you all how he went about achieving the impossible and repairing an infusion gone wrong. MORE INFORMATION can be found on our website https://youngbarnacles.com MUSIC https://www.youtube.com/

Our deep dive into answering those questions regarding the implosion of our box beam while it was under vacuum. MORE INFORMATION can be found on our website https://youngbarnacles.com MUSIC https://www.youtube.com/

This video covers the build of the structural box beam in the master cabin. There is 5mm of unidirectional eglass being applied to both hull and box beam, so there is A LOT of fibreglass in this lamination. Because of this, Shayne is going to infuse this part. There is a lot of work in preparing the existing surface, building the foam box frame, and preparing for infusion. Actually, it was a week's worth of work, and as you can tell from the thumbnail for this video, the infusion did not go to plan. We knew that there was a risk that if there was a leak anywhere between the hull and the box beam we were installing, then there would be a vacuum inside, and it would collapse the beam. So, grab your drink of choice and sit back for 33 minutes of engineering tech talk finishing with an infusion implosion that should please the more geeky members of our audience out there. Spoiler alert - it was not all doom and gloom as Shayne was able to rebuild the box beam afterwards - however, that explanation is for the next video. MORE INFORMATION can be found on our website https://youngbarnacles.com MUSIC https://www.youtube.com/

Join us for an in depth discussion on carbon lamination while Shayne laminates the very last carbon stanchion socket on Paikea. This episode is for those who want to learn more about the lamination and vacuum bagging process. We talk through every step in and share some top tips on what you should know if you want to be successful in your lamination projects. Curse of the Dreaded Peel Ply article can be found on our website https://youngbarnacles.com/free-resources-2/working-with-composites/ What is Peel Ply? Peel ply is a fabric, typically nylon or polyester, that is applied to the surface of a composite laminate during fabrication. It's designed to be removed after the resin has cured, leaving behind a textured surface that is ideal for bonding or applying subsequent layers. The "Curse" The "curse" arises from several potential issues associated with peel ply: Adhesion Problems: Some resin systems may not bond well with the peel ply itself, leading to adhesion failure between the peel ply and the laminate, or between the laminate and subsequent layers. Surface Contamination: If not properly removed or if the wrong type of peel ply is used, it can leave behind residues or contaminants that hinder bonding. Fiber Breakout: Improper removal of peel ply, especially at high peel angles, can cause fiber breakouts, weakening the surface and affecting its bonding capabilities. Surface Irregularities: Even when removed successfully, peel ply can leave behind a textured surface that may not be perfectly smooth, potentially requiring additional surface preparation before bonding. Why is it a "Curse"? The "curse" is not an inherent property of peel ply itself, but rather a potential outcome of its improper use. It highlights the importance of: Selecting the right peel ply: Choosing a peel ply compatible with the resin system being used is crucial. Proper application and removal: Following recommended procedures for applying and removing peel ply is essential to avoid contamination and damage. Understanding the limitations: Peel ply is not a universal solution for all surface preparation needs and may require additional steps for optimal bonding. In essence, the "curse of the dreaded peel ply" serves as a cautionary tale, reminding composite manufacturers to be mindful of the potential pitfalls of peel ply and to take the necessary steps to ensure its effective and reliable use. MORE INFORMATION can be found on our website https://youngbarnacles.com MUSIC https://www.youtube.com/

The whole build process! Follow along as Olly learns how to build a foam/carbon pumpboard. If you want to see more details watch the first part of the build here https://youtu.be/qa98eXUYKn8 Olly wants to set a world record for pumpfoiling. If you want to learn more about his plans subscribe to his channel @OliverYoung-h3p MORE INFORMATION can be found on our website https://youngbarnacles.com MUSIC The talented Kenneth Penman is a friend and fellow boat kid. Be sure to check out his YouTube channel @KennethPenman and subscribe to help his channel grow.

We're having a look at our doors in more detail - these are custom made and built for purpose. Depending on the job the door has to do would depend on the build construction and locking mechanisms we use. MORE INFORMATION can be found on our website https://youngbarnacles.com MUSIC https://www.youtube.com/

POV When you get carried away with making something cool and then realise you have just managed to make life hard for yourself. This week we are working on doors and rewiring cables through the main cabin. Anna is fairing any clean surface she can find and Shayne seems to think he is on the Starship Enterprise with a project he soon regrets starting. MORE INFORMATION can be found on our website https://youngbarnacles.com MUSIC https://www.youtube.com/

14 year old Olly has been collecting scraps of foam and carbon from our Paikea refit and has decided the time has come to make his own carbon pump board. The skills he has been learning helping with the modifications on Paikea means that he is already familiar with materials and processes so this is the logical next step for him. He has done a fantastic job filming the process so you can all follow along with the build.... and listen as Shayne gives guidance throughout this very cool project. Tune in next week to see the next steps Materials used for this project can be found at Easy Composites EU @easycompositestv MATERIALS LIST PVC CLOSE CELL FOAM https://www.easycomposites.eu/easycell75-closed-cell-pvc-foam EL2 EPOXY LAMINATING RESIN WITH BOTH SLOW AND FAST HARDENERS https://www.easycomposites.eu/el2-epoxy-laminating-resin CARBON FIBRE CLOTH 200G https://www.easycomposites.eu/200g-black-stuff-22-twill-3k-carbon-fibre-cloth *we are still experimenting with this - it may be worth going a heavier cloth as we have flex in the board BREATHER FABRIC https://www.easycomposites.eu/breather-fabric VAC BAG https://www.easycomposites.eu/vb160-vacuum-bagging-film PEEL PLY https://www.easycomposites.eu/pp180-peel-ply TACKY TAPE https://www.easycomposites.eu/vacuum-bagging-sealant-tape PERFORATED RELEASE FILM https://www.easycomposites.eu/r120-perforated-release-film MORE INFORMATION can be found on our website https://youngbarnacles.com MUSIC https://www.youtube.com/

Unless you are a composites engineer yourself then this episode is not one we recommend you try at home. This week we are widening the doorway through the bulkhead - but this bulkhead has a carbon fibre chainplate built into it and we are going to cut super close. Why? We want to open up the space to make Paikea's narrow hulls more accessible and easier to walk through, but it is more than just taking the jigsaw to it. This area sees some serious load and by cutting into this space we need to know what we are doing. There is always a great deal of thought and calculations that go into each of our projects. Shayne makes it look easy but he has done this stuff a million times before (gotta admit it still makes me nervous looking how close we go to the chainplate!). As you may have already figured, we are not the average DIY boatbuilder on YouTube. Hopefully our videos will inspire others but we absolutely recommend talking to a composites engineer before you tackle anything as serious as what we are up to here. That being said, the end product looks fabulous and the bulkhead now has unidirectional fibre running along the entire doorway with edge capping to finish it off. Happy days. If you are interested to see the lamination of the doorframe in more detail an explanation of our methodology can be seen on our videos on re -engineering the doorframe - see the links below https://youtu.be/YoHUB7iZU4g https://youtu.be/Pvfkim9rvIY We tried filming some of this with our new insta360 but some footage came out a bit wonky so apologies everyone. We're learning as we are doing on the filming side of things. For the bulkhead edge capping we used vinlyester resin from Easy Composites @easycompositestv More info as always on our website https://youngbarnacles.com MUSIC https://www.youtube.com/

Following on from our video on composite stanchion sockets, we are exploring what material is best for each job in your lifeline system. We built carbon fibre sockets but kept our stainless steel stanchions, which seems like a low tech solution considering we have made a living working with composites. So what was the thought process behind this decision? We had a lot of questions last week after the release of our building stanchion sockets video so this week we are trying to cover the bits we missed out. The drainage setup for internal sockets, how are we going to secure the stanchions in place and why you should be really careful about using carbon fibre in an application. Many people assume that carbon is better than steel but they are very different materials and behave in very different ways. For those of you who enjoy the tech side of sailing, here is another thought provoking video on choosing the right materials for lifelines. Check out more at https://youngbarnacles.com MUSIC https://www.youtube.com/

A deep dive into stanchion sockets, stanchions and preferred materials. This week we are looking at everything you need to know (or at least giving you a good nudge to investigate further) about lifelines, stanchions and how to connect it all correctly and SAFELY to your boat. Stanchions are a safety feature so its not a matter of finding the cheapest solution - this one is finding the safest and most reliable. We hope this information will help those of you wanting to some techy info on what you should be looking for. Heaps of information on this one and we will be adding more to our website https://youngbarnacles.com/making-composite-stanchion-sockets/ and some good stuff on our members page www.youngbarnacles.com if you want to dig deeper into the topic. We used carbon tube, release wax and resins from @easycompositestv European division. https://www.easycomposites.eu/ References https://www.sailing.org https://www.iso.org/standards.html ISO 15085:2024(en) Small craft — Protection from falling overboard and means of reboarding Fred Barrett Yacht Design https://fb-yd.com/ Brett Van Munster https://vanmunsterboats.com/ Matthew Smith https://csparnz.com/ More information on our stanchions can be found on our website below https://youngbarnacles.com MUSIC https://www.youtube.com/

In this episode we are putting in the last piece of the new floor in Olly's room, covering over the newly created crash box behind the daggerboard case (I called it a wet box in the video so well done to those of you who noticed my mistake. A wet box stays wet whereas the crash box is designed to hold water if the part its protecting fails). We are now on to installing new fuel tanks as the stainless steel ones we originally had have corroded and are now starting leaking. It seems Paikea knows we are fixing things and is determined to add her own desired upgrades to our list! There's a whole lot of information in this one including our preferred composite materials supplier here in Europe - A BIG shout out to Easy Composites Europe for all your good work. (Full disclosure - we don't get any sponsorship deals but they do give us the regular trade discount). We have been struggling to find reliable suppliers here in Spain. Most places want you to purchase in bulk or just can't supply the materials we are after so it has been so good to find someone who can assist with our needs and do it so quickly and efficiently. They also have a great YouTube channel which we have featured on our website as we do think they are a valuable resource for anyone looking for good composite advice. You can check them out on our resources page or go straight to their website here ​https://www.easycomposites.eu/ ​ We've got a heap of tech stuff in this installment so get your coffee and tell the kids to be quiet - Shayne is going to tell you WHY we are infusing all these parts for Paikea rather than hand laminating everything. Is it worth the extra hassle? We think so and in this video we'll tell you why. Feel like supporting us? Buy us some carbon - we'll put it to good use https://youngbarnacles.com MUSIC https://www.youtube.com/

While we have the old floors out and are upgrading the bulkhead next to the keel, Shayne has decided to increase the safety margins around our daggerboards by adding a crash box behind the daggerboard case. This is a safety feature just in case we hit something with our daggerboards, and it breaks the case and lets in water. It just seems like a sensible thing to do since we are rebuilding everything else around this area. It's taken a while to sort this piece out as it is fiddly and in a difficult position, but we are feeling much better about the structural integrity around the daggerboard case now. And now we can finally start gluing the new floors in! www.easycomposites.eu Feel like supporting us? Buy us some carbon - we'll put it to good use https://youngbarnacles.com MUSIC https://www.youtube.com/

Lots of information on daggerboard case loads and how we are improving load distribution in Paikea. Feel like supporting us? Buy us some carbon - we'll put it to good use https://youngbarnacles.com MUSIC https://www.youtube.com/