Rebuild
After discovering the true underlying condition of the vessel the process of restoration began.
Essential repair work was costly, but cutting corners in the rebuild process would have been a false economy. No one with an ounce of integrity would knowingly sell a yacht with a fractured keel without disclosure. Note: "Show More" button at page bottom.
Hull plates on port and starboard sides were replaced.
New steel plates being installed port and starboard.
New steel plates in the bow
New steel plates in port side
Keel being cut prior to Orion being lifted away. It would be unethical and unthinkable to knowingly sell a vessel with a damaged keel.
Damaged keel was cut from the hull and Orion lifted.
Orion being lifted from the forward keel section
Diesel tank being rebuilt, new bulkheads and removable inspection plate.
The damaged keel section was removed and transported to the Tekkocan workshop. Lead ballast had to be removed, cleaned and prepared for the new keel.
Tekkocan engineers made a wire frame template for the new keel construction.
Tekkocan engineers made a wire frame template for the new keel construction.
Tekkocan engineers made a wire frame template for the new keel construction.
Tekkocan engineers made a wire frame template for the new keel construction.
A new keel was constructed based on the original and the wireframe template. Original 7mm steel plate replaced with 8mm plate. The keel base was constructed with 12mm steel plate. Two coats of Owatrol CIP applied to keel interior.
Original ballast was gradually added to the new keel.
Original ballast was gradually added to the new keel.
Original ballast was gradually added to the new keel.
Original ballast was gradually added to the new keel.
Original ballast was gradually added to the new keel.
Original ballast was gradually added to the new keel. Shingle shot added to fill voids and then compacted with a vibrator.
New keel was positioned and Orion lowered on top. A backing weld was used and the fit was millimeter perfect. The design and weld procedure was recommended and approved by Dick Koopmans himself.
New keel was positioned and Orion lowered on top. A backing weld was used and the fit was millimeter perfect. The design and weld procedure was recommended and approved by Dick Koopmans himself.
New keel was positioned and Orion lowered on top. A backing weld was used and the fit was millimeter perfect. The design and weld procedure was recommended and approved by Dick Koopmans himself.
New mast footings manufactured from aluminium.
Stainless steel rod at top of gunwale caused some galvanic corrosion.
Gunwale design modified. Stainless steel rod at top of original gunwales caused galvanic corrosion. L-shaped steel contoured and added to create extremely strong gunwales.
Old deck fixings removed and all holes filled with weld.
All deck fixing removed and filled. Genoa track had 8 cm bolt spacing which no longer exists. Original plan was to weld up the deck ready to accept new genoa track with standard 10 mm spacing, however the plan is to replace the genoa track with a "twing-outhaul", leaving the decks totally clear and flush.
Rigging deck loops replaced by stainless plates positioned on top of new gunwales. This leaves the decks completely flush and free of all obstruction. redesign approved by Dick Koopmans.
New gunwales integrated into bow area, and reinforcing beyond the original design.
Lazarette refurbished with new steel and primed.
New stainless step design for safe access into lazarette. Exhaust sits behind the steps.
New rudder support and pack-off prior to fitting through the hull. Area will be blasted, primed and epoxied.
New 60mm rudder stock
New keel starboard quarter
New keel port fore-quarter
Port side with new steel plates (8 mm)
Rudder lower bearing being prepared. Teflon insert with brass ferrule to accept 60 mm stainless rudder stock.
New lower rudder bearing being tested with new 60mm rudder stock.
Upper rudder stock test fitting for new through hull tube.
Integral water tanks removed and new hull plating. Floor beams and supports for new PTFE water tanks in place.
Integral water tanks removed and new hull plating. Floor beams and supports for new PTFE water tanks in place.
Original fixed high level platform removed and adjustable swim platform installed.
Lower bow being prepared for bow thruster tube. A bow thruster was planned well before the litany of problems were discovered.
Aperture cut for bow thruster tube.
Bow thruster tube being installed
Bow thruster tube installed
Bow thruster deflector wire frame being designed.
Bow thruster deflector plate starboard side