The vessel, SELF RELIANCE, a CT-49, owned by Dave Weisher of Bowie, Maryland, was seen by our firm on February 26, 1994, in order to ascertain whether repairs and modifications, up to this point, meet the engineering and execution standards suggested in our previous visits. At the same time, we were afforded the opportunity to examine areas which were normally under structural/semi structural members and to be able to further evaluate these areas for structural integrity. At our request, we were also provided with a bill of materials and lay-up schedules for the structural work completed and underway.

Physical Findings:

The interior of the vessel has been fairly well stripped back, including removal of the main cabin sole, also relevant portions of fore and aft sole areas, deckhead covering, hull coverings.

Rebuilt mast step

The mast step area has been re-engineered and re-built in accordance with the recommendations made by this firm at the initial examination of this area and subsequently in verbal conference with Mack Horton. The new step has been structured with 2 layers 15 oz bi-directional E glass waterways; 1 layer 24 oz roving on all faces; 2 layers 15 oz bi-directional cloth, 1 layer 24 oz woven roving top of web; 1 layer 15 oz full; 1 layer 24 oz web top; 1 layer 15 oz full; 1 layer 24 oz full; 1 layer 15 oz full; 3 layers 15 oz tape; 1 1/2" set in fiber mush, 1 layer 24 oz cloth to cover plate.

New floors

New floors were added under the sole in the main cabin area. This will extend the area over which the rig stresses are borne, thereby eliminating the hull stress previously encountered.

The new floors were laid up with the following schedule: 2 layers of 15 oz, waterway; 2 layers 15 oz tape, bottom; 1 layer 24 oz, faces; 1 layer 24 oz, top; 1 layer 15 oz, full, 1 layer 24 oz full; 1 layer 15 oz, full. The lay-up was made over beam form sections to create a strong rigid integral structural web, with staggered seams to prevent stress concentration areas.

Bulkhead delamination repair

The bulkheads which had shown tab delamination and movement have been sistered and reinforced at the hull attachment joint. The sister is constructed of 3/4" marine plywood screwed and glued with fiber thickened epoxy to the bulkhead. The taping schedule for the bulkhead is: 1 layer 15 oz; l layer 24 oz; 1 layer 15 oz.

Deck

Teak overlay has been removed. This gave us a chance to thoroughly sound the whole deck and to electronically read moisture levels in the deck core. There are certainly some areas of higher moisture. Several of these have been opened and are being dried out. The surveyor has interviewed the firm building the teak deck and is fully satisfied with the products and the workmanship as exemplified by sample work shown to our firm. The proprietary sealant and caulking is particularly good, seeming to have an unusually good resistance to stress and shrinkage loads. We are also impressed with the use of a fiber backing and the ability to set a few fastenings well down, eliminating the problems with shallow fastenings "poppin" their plugs and allowing water ingress.

We also discussed and agreed to a method of inserting some extra deck beaming to help alleviate the spongy deck on the cabin top where the laminate is thin and the deck not very well reinforced.

Costs

I have been asked to estimate the cost of work to date based on the general labor rates in yards in our area. To this end I have offered the following, which is based on the published prices of the yards in our general area, and material costs based on general wholesale plus usual yard markups of the material list which I was given. Amounts are rounded to the nearest; $10.00.

Materials: $1940.00
Labor: based on 72 hours removing interior and 200 hours rebuilding: $7,720.00 Total to date: $9,660.00

The above report is offered without prejudice. The surveyor has no personal or financial interest in either the vessel or in any firm associated with it's repair, or with any firm used for comparison pricing purposes.

Graham S. Byrnes, N.A.
Carla S. Byrnes, Surveyor
March 8, 1994

B & B Yacht Designs 202 Elm Street
Vandemere, North Carolina 28587
(919) 745-4793