MJ Sailing · video

What this video covers

The exterior of the catamaran is undergoing a transition from gel coat to a painted finish using Alexseal 501 topcoat.0:11 Because the hull is foam-cored fiberglass, the crew is rolling the paint rather than spraying to avoid overspray on neighboring vessels.2:04 To ensure a smooth finish, they are applying multiple coats of primer to eliminate print-through from the underlying fairing compound.2:00 The cockpit floor and helm area are also being faired with TotalBoat polyester fairing compound to flatten uneven surfaces.5:44

Installing simple push-button momentary light switches requires a multi-day process due to the boat's foam-core construction.7:22 Because the switch barrels are too short for the 16mm-thick fiberglass panels, the crew must decore the area and bond a custom-fitted insert to reduce the panel thickness to 10mm.8:39 This insert provides the necessary depth for the switch nut while maintaining structural integrity.8:44 To prevent surface distortion or paint ripples, the crew carefully avoids drilling too close to the outer skin.12:01 The final installation involves using a 19mm hole saw in reverse to minimize abrasion before securing the switch and routing the wiring behind the panel.14:28

More from MJ Sailing

Painting the Accent Walls On Our Home Built Catamaran (MJ Sailing - Episode 380)Jul 2026The Details That Keep a Boat Dry (MJ Sailing - Episode 379)Jun 2026Preparing Our Catamaran for Paint—and Me for Captain's SchoolJun 2026The Bad News: We Have To Cut This Bulkhead Out (MJ Sailing - Episode 377)May 2026

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