This video documents several critical projects undertaken during a major refit of the sailing catamaran Sabado while it is hauled out in New Zealand. The central focus is on addressing a serious and widely recognized safety issue with the vessel's waterline escape hatches. The creators detail the inadequacy of the manufacturer's original recall fix—two small aluminum brackets—and showcase their robust solution: custom-fabricated, heavy-duty stainless steel brackets that frame all four sides of the hatch to prevent catastrophic failure.
Alongside this critical safety upgrade, the video covers several other significant refit tasks. These include the DIY reconstruction of a bed base using marine-grade plywood, which is being prepared to house a new electrical system. The couple also has a crucial stainless steel handhold near the helm professionally re-welded to correct the original weak "fusion welds." Finally, they remove their stretched-out mainsail for replacement and prepare for the mast to be pulled the following week to fix internal loose wiring.
Catamaran Refit: Tackling Critical Safety and Maintenance Projects
0:55 Critical Handhold Repair: A dangerously weak handhold near the helm is professionally repaired. A welder explains the original "fusion welds" lacked strength and reinforces the structure for safety during rough weather.
2:42 DIY Bed Rebuild: Using high-quality marine-grade plywood, the couple begins rebuilding their bed base. This new structure is designed to be stronger and will house their future electrical system.
7:04 The Escape Hatch Problem: The video identifies a major safety concern with the catamaran's escape hatches, which are positioned at the waterline. A previous manufacturer recall provided a flimsy and inadequate "fix" consisting of just two small aluminum brackets.
7:33 Mainsail Replacement: The mainsail is removed to be replaced. After nearly 30,000 nautical miles, it has become so stretched that it compromises sailing performance and puts dangerous stress on the rigging.
8:02 Mast Preparation: In preparation for work the following week, they remove the sails to get ready to pull the mast. The goal is to fix loose wires that have been clanking around inside it.
10:14 A Serious Design Flaw: Ray expresses significant frustration with the escape hatch design, stating more boats have been lost from their failure than people saved by them. He demonstrates how easily the manufacturer's fix (the tiny aluminum brackets) can be removed.
12:00 A Custom Safety Solution: Since fiberglassing over the hatches would compromise the boat's CE rating, they opt for a custom solution. They have long, heavy-duty stainless steel brackets fabricated to frame all four sides of each hatch, ensuring the glass cannot fall out even if the adhesive fails.
12:41 Future Workshop Build: The couple announces they have hired a carpenter to begin building out a workshop in one of the cabins, signaling the next phase of their refit.