Sailing Magic Carpet · video

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The owners of a Cape George Cutter 36 are rebuilding the vessel's bulwarks to eliminate chronic water ingress points that previously damaged structural deck beams and blocks. The refit replaces original wood construction with foam-core bulwarks, which are fully encapsulated in fiberglass. To prevent future leaks at scupper penetrations, the process involves drilling and hollowing out the bulwarks, then applying multiple layers of fiberglass to the interior perimeter before wrapping the entire structure. Custom bronze chain plates from Port Townsend Foundry were installed with specific hole spacing to avoid deck-level penetrations near the beam shelf. To prevent foam compression during through-bolting, the crew filled drilled holes with high-density epoxy filler using a needle-injection technique. After completing the fiberglass work on the bulwarks and transom, the next steps include fairing, priming, and painting the surfaces before installing the teak toe rail.11:30

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