Hull refurbishment of a Hallberg Rassy 37 by Deacons Marina Boatcare

A Hallberg Rassy that used to berth with us, returned with the new owner for a full hull refurbishment, seacock replacement and Coppercoat application, leaving her looking factory fresh.

This hull refurbishment included large white gel repairs to the port side and stem, including blue painted lower stripes. On the starboard side we repaired the blue top gel stripe  – on this model of Hallberg Rassy, top stripes are always gel and the lower stripes painted. This blog details the process followed.

The boat arrived with damage to the stem, due to anchor deployment over the years. A previous poor repair to the starboard side top stripe had resulted in it shrinking. At some point she had experienced damage to the white gel of her port side – running right through the two blue painted lower hull stripes and then down in to the old Coppercoat.

GRP specialist Deano began by sanding back both the stem and a large area of the damaged white port side, using progressively finer grades, before filling and fairing to a completely smooth finish. The stripes had to be removed in the process. White gel was applied in several layers before fairing and polishing to a factory smooth finish, before work to reapply the stripe could begin.

To apply the new lower stripes, one at a time, the entire yacht was tented in, over the deck and down over the hull and keel to protect her from overspray. Tape was used to mark the area for stripe application. We spray applied colour matched paint in several coats, the result being two beautiful lower stripes.

Finally, we rectified the shrunk top stripe to the starboard side – a previous poor repair having left an imperfection in the otherwise immaculate gel. We sanded back the previous repair, keeping inside the blue stripe. Several coats of blue gel supplied by Hallbery Rassy were built up in layers before fairing with progressively finer grades, to blend in the repair. The final layer of gel has a wax additive mixed in, to ensure it goes off.

The final result is a factory fresh Hallberg Rassy, looking beautiful and ready for the season ahead.