Valiant Restoration

Fast forward to 2008:

Good news:

I finally found a 1977 Valiant 40 I could afford.

Bad news: She was very needy. Amulet was built during the infamous “fire retardant resin era” of the Valiant history (blue water boat.org). In addition to having the unsightly but non structure blistering, resulting from the fire-retardant resin; she had been badly let go. Water had intruded the Balsa deck core in so many places that the entire top layer of the deck had to be completely removed and all the Balsa core beneath it. Nothing was spared including, the side and fore deck, cabin top, cockpit sole and cockpit seating areas.

All these areas were re-cored with Core Cell set in thickened epoxy and covered by 2 layers of 1708 biaxial fiberglass cloth. A final layer of 18oz boat cloth was laid on top and then vacuum bagged down to facilitate bonding. In the process, the head sail tracks were recessed into the core of the side decks; along with the mid- deck drains. The cockpit had a large raised propane locker behind helms seat, limiting where one could sit. This has been removed and a plug was taken from another locker top. Now a new locker was created and making a flush seat for the helmsman that, when opened, offers clear access to the new steering radial and wire below. The large propane locker was then cut in two and reused. Each part became the new propane boxes that contained drains in the “corners” of the canoe stern with custom locker lids made for them.

Spraying down Awl Grip was considered for the bright sections of the deck but frankly, I’m not a great painter and didn’t feel I would be satisfied with the outcome. I ended up back to the tried-and-true use of gel coat. It can be tricky

spraying gel coat too but using a 50/50 mix of DuraTec high gloss additive, the gel coat finish comes out surprisingly smooth. The best part is that any mistakes can be sanded out as the area all gets sanded to 6000 grit to make it shine and then polished. All non-skid sections were sprayed down with a colored gel coat with micro-ballons added for traction.

The water seepage from the deck had ruined the headliner below and damaged two structural bulkheads connected to the chain plates. The horizontal fur strips of the interior (ceilings) were also badly stained, about 100 sq ft of replacement ash strips were cut, sanded and polyurethane is before reinstallation and new Formica on plywood was made for the headliner. The interior was so spartan at one point that the teak of the interior was cleaned with that nasty two-part teak cleaning acid, a scrub brush, and hosed down.

As with most major projects, once the rework begins it is very hard to stop. The vessel originally had 9 plastic ports on the house sides and 4 wooden deck hatches. The 9 cabin ports were replaced with 14 stainless New Found Metals ports. Adding more ports meant re-configuring their spacing in the cabin sides. The wooden hatches were replaced with stainless Mann Ship hatches.

The DC electrical systems as well as electronics were also aged so while the boat was pulled apart, every inch of plain copper wire has been removed and replaced with new tinned wire, installed to ABYC standards with a new electrical panel. The batteries were located in the wonderful engine room of the Valiant 40 but that location is way too hot for them over time. Now there are now 8 group 31 AGM batteries aboard. 4 are in hanging locker and 4 are under the aft cabin berth with a start battery under the companionway step. To charge these banks, besides a new 110-amp new Balmar alternator, there are 5 Flexible 100-watt solar panels are on the bimini top of the new stern stainless-steel arch a 175-watt panel is on top of the ridged dodger I built. The ridged dodger is supported by another hefty custom stainless-steel arch that is sized to accommodate the main sheet and traveler.

All of the plumbing was removed and replaced as well as every thru-hull, pump, faucet, propane hose, holding tank, deck fill and deck drain. The two original aluminum, 75-gallon water tanks leaked and would not fit out the companionway so were cut up for removal. Consequently, the new tanks were fabricated in place using Cusa board and FDA approved epoxy from MAX BOND. The bladder waste holding tank was tossed and a custom stainless-steel tank was installed. The aged refrigeration system was replaced with two Sea Frost units; 1 fridge and 1 freezer. The 9-gallon fuel tank was suspect and the tank was cut out to remove. Two new aluminum fuel tanks were fabricated from my templates and the cockpit side was cut to install them.

The mast system was upgraded with new rod rigging and the mast was rewired and painted. New chain plates we waterjet cut to reduce stress on the metal and polished to resist pitting over time. The sails are mixed but the main is new.

Her bottom was sand blasted and re-faired with thicken epoxy. Her rudder had some voids so it was removed, pealed, re-glassed with epoxy and is good as new.

She had a 1999 Beta Marine 43 diesel engine that was started once a year over the ten-year refit. But once launched the transmission and gear needed rebuilding and a new shaft, cutlass bearing, and stuffing box was installed.

She now has a full suite of B&G electronic including Zues 3 plotter, HALO 20 Radar, Auto Pilot, Triton depth, wind and boat speed, AIS, boat base computer, VHF, and Starlink

😊 She is Not for Sale 😊

If you think I’m qualified to look at your boat, please call for an appointment Many Thanks,

Joe Grenier

978-317-5670