The Boat Is Finally Back in the Water!

On Friday, May 23rd, 2025, Stormtrooper finally made her way back into the water!

In this log, we’ll share why we had to haul Stormtrooper out for emergency repairs. It also documents the repair methods we tried and the types of paint we used.

More than just a simple experience share, this log will also help us track the details of the maintenance work for future reference. That way, we can keep improving and fine-tuning our process over time.

Emergency Alert: The Boat Was Sinking!

It all started on January 21st. We were just about to head off the boat to visit friends in Bloomsbury. Fortunately—or perhaps unfortunately—just as we stepped into the dinghy, Chris noticed the engine room's bilge pump was running. (This meant there was a significant amount of water in the engine room—definitely not normal.)

We rushed back on board and opened the engine hatch. To our shock, we saw seawater flooding in through the return line of the fuel system. That meant a hole had formed somewhere in the hull, allowing seawater to enter the fuel tank, and from there, seep into the engine room via the fuel lines.

Thankfully, the fuel filter did its job— it stopped the saltwater from entering the engine itself and diverted it through the drainage system. A close call!

However, technically —we were sinking! (At the time, we even had two German backpackers staying on board. They were so calm after being told the boat was taking on water.)

We contacted local boatyards and confirmed that Edge’s Boatyard had availability. It's located on a river inlet at Funnel Bay, just before the sea mouth. However, a sandbar lies at the entrance, so boats with deeper drafts can only pass at high tide.

After checking tide charts, we realized January 29th was the soonest we’d have enough depth to bring Stormtrooper in. That same day, Chris temporarily sealed off the return line to stop the flooding. On the morning of the 29th at 10:00 am, with help from our friend Stuart, we safely docked at Edge’s Boatyard.

Edge’s requires a minimum stay of three months and full insurance coverage. So we decided to leave Stormtrooper on the hardstand through to April and take our time with repairs.

But… summer in Airlie Beach lasts until May. The first two months were filled with rain, making welding and painting nearly impossible. Eventually, we had to extend our stay by one more month. Finally, on May 23rd, Stormtrooper went back into the water!

What Caused the Leak? Electrolytic Corrosion!

The main culprit was electrolytic corrosion—all the sacrificial anodes had completely dissolved. The steel hull had developed multiple pits (I made a joke about calling Stormtrooper a “Vietnam War survivor”). Two of them had fully breached the hull and corroded right through the fuel tank.

After some investigation, we realized the tank’s layout was tricky. If we tried welding without fully draining the diesel, there was a risk of explosion. In the end, a boatbuilder friend helped patch the holes. He first sandblasted the surrounding area, applied an ultra-strong marine epoxy, and sealed it with a steel plate, filling the edges with epoxy again.

According by our friend, this type of epoxy is so robust, it can even be used for underwater repairs once cured!

We were impressed by its performance. Chris later picked up a similar product at Bunnings. He welded where he could, then applied epoxy to finish off the rest of the repairs.

Note:

We are not professionals—we're learning as we go. The repair methods we used are based on our own experience and may not be the “best” or “correct” approach. We’ll continue sharing updates on the hull’s condition in case they’re helpful (or cautionary!) for other boaties.

If you’re an experienced sailor or repair expert, we’d love to hear your thoughts—as long as they’re kind. Let’s keep the sailing community supportive and collaborative.

Hull Repair Process and Products Used

Repair process:

• Sanded the hull down to the pink primer layer

• Cleaned rust and pitting on corroded areas

• Filled pits with welding / epoxy (Deks Duobond 2-part Epoxy)

• Applied epoxy paint: Jotamastic 90 (2 coats red, 2 coats grey)

• Applied tie coat: Vinyguard Silvergrey 88 (1 coat)

• Applied antifoul: SeaQuantum Spectrum Black (1 coat)

Diagram of layers:

Other Highlights from Our Time on the Hardstand

1. Aluminum Anodes

   While searching online, Chris came across studies showing that aluminum anodes perform well, and many boats in New Zealand use them instead of zinc. Surprisingly, no one in Airlie Beach seemed familiar with them, and many were skeptical. So we decided to run a long-term test. We’ll regularly check their condition and haul the boat again in January for inspection.

   
   

   

   
   

2. Cleaned and repainted the hull interior

   Re-routed and reinstalled some plumbing lines.

   
   

3. Repaired and painted the toilet floor
   

4. Rewired the 240V circuit Ensure all cables are secure and no longer in contact with the steel hull—safety first before heading back on the water!
   

5. Installed a new 12V USB charging port Thanks to Chris, it's now super convenient to power up devices while working.
   

6. Revamped the tool section and the storage space underneath everything’s now neat, organized, and fully functional again!
   

7. Got a portable air conditioner!

   This little unit blew away our expectations—it works amazingly well!
   

8. Modified my workspace storage

   I converted the top-lid storage next to my workbench into side-opening drawers. Much more practical!

Final Thoughts

I owe a huge thank you to my partner Chris for his dedication over the past four months. After we extended our stay at the boatyard, I decided to take on part-time work to help cover costs. That meant Chris had to complete most of the repairs alone during the final two months—and he did an incredible job.

Our time at Edge’s Boatyard was truly wonderful. The neighbors were kind,, and the staff were always helpful. We’re incredibly grateful for everyone’s support, and we genuinely look forward to returning next year.

The only downside? Queensland summers come with a plague of midges!

Edge’s is surrounded by mangroves—a prime breeding ground for these little monsters. I’ve lived in Airlie Beach for over three years, and still find these bites insanely itchy—way worse than Taiwan’s no-see-ums!

If you're visiting Airlie in summer, bring insect repellent. Trust me.