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A Beneteau First 47.7 delivery from the Bahamas to Cartagena, Colombia nearly ended in keel loss when the hull-to-grid bond failed at sea. James Evenson, hired to deliver the 48-foot racer-cruiser, encountered building trade winds south of Haiti — 35 knots gusting to 40 — and noticed the bilge pump cycling every 15 minutes.2:26 By the final night, 90 miles offshore, floorboards were floating, the crew was hand-vacuuming bilge water in relay, and the house bank died, killing the autopilot, GPS, and lights.4:00 The water source was seawater seeping up through keel bolts whose bedding had cracked as the internal grid separated from the hull along nearly half its length.11:48

Hauled at Marina Manzanillo in Cartagena, the boat showed the grid detached from the hull from the rear keel bolt forward, the forward compression bulkhead cracked at the mast step, and both forward bulkheads disconnected.11:17 Evenson explains the failure mechanism in detail: production boats under 50 feet typically bond the prefabricated interior grid to the hull shell with methacrylate glue alone, and on a high-load design like the 47.7, repeated torsional stress from a nine-foot keel in beam seas progressively fractures that bond.9:34 He connects the incident to the 2014 loss of the Cheeky Rafiki, a sister-ship Beneteau First 40.7 whose keel separation killed four crew.16:38 A crack at the mast step on the forward compression bulkhead is the key visual warning sign.13:23 Proper repair requires removing the entire interior and glassing the grid to the hull — a job Evenson estimates exceeds $100,000 and causes most affected boats to be scrapped.15:09

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