Part 2 of our three-part series following the Bluewater preparation of Constance, a Swan 441 preparing for a three-year circumnavigation, looks at the major technical work completed during her winter yard period.

By the time Constance came ashore, we already had a clear picture of the work ahead. The Readiness Assessment, hull and rig surveys had helped establish the priorities, so we were perfectly placed to use the winter to complete the technical work before sailing resumed in spring.

Preparing for Bluewater sailing requires a different mindset from routine maintenance.

The question isn't simply: does it work now?

It's: will we be happy to rely on it for the thousands of miles we plan to do? 

Investigating beyond the obvious

From our initial investigations we had already recommended replacing Constance's corroded propeller and worn cutlass bearing. Once work began, however, we identified additional play and discovered that the prop shaft was bent and the stern gland leaking.

For coastal sailing, the owner might have chosen to monitor the situation. 

A bent shaft creates vibration, accelerating wear on the cutlass bearing and shaft seal and placing additional loads on the engine mounts and gearbox. Over a 3-year circumnavigation covering around 35,000 miles, that would create significant additional wear across many aspects of the boat. We therefore replaced it.

The engine investigation followed the same principle. We deliberately conducted a thorough engine service prior to lifting the boat which enabled us to identify any issues early, and to work on them during the yard period. The service identified corrosion in the heat exchanger and a weeping raw-water pump caused by wear to its shaft. Although not critical issues at this stage, both were addressed rather than waiting for them to become problems later at an inconvenient location.  

The rudder was removed during lift-out, and during the yard period we made inspection holes to assess its internal integrity.  In this case, everything was sound – which is just as valuable to know before setting off around the world.

Designing systems for life offshore

Another aspect to the project was about making Constance more capable and self-sufficient during her planned world cruise. 

Power generation was a major consideration. We installed flexible solar panels to generate power without needing to rely on the wind, perfect for Caribbean cruising and for use whilst at anchor.  

We installed a Remoran hydrogenerator to generate electricity while the boat is moving, regardless of sunshine. The perfect pairing to cover most scenarios.

Together, these reduced dependence on running the engine purely to charge batteries – saving fuel and engine wear while supporting the significant electrical demands of long-distance cruising and allowing the owner to be able to confidently run multiple systems simultaneously including refrigeration, autopilot, navigation equipment, satellite communications and interior and exterior lighting.

A Hydrovane wind steering system provided another way of reducing reliance on electrical power. It can steer the yacht to a set wind angle independently of all the other yachts systems (including the crew!), while also providing an independent back-up steering option if any part of the main steering system or rudder were incapacitated.

Refrigeration was upgraded for the warmer climates ahead. We retained the existing coolbox but replaced the compressor and pipework with a keel-cooled system. 

Knowing much of the planned Bluewater adventure would take place in warmer climates, being able to use the cooler seawater rather than warm ambient air would facilitate a more efficient heat dissipation. 

Preventing problems before they happen

For a three-year voyage, small sources of wear can become big problems.

Some of the solutions are more obvious: We fitted chafe-resistant Dyneema halyards and UV-protective covers for deck equipment and new sails. We also upgraded to high-volume bilge pumps as a safety precaution.

Removing Constance's keel-stepped mast also uncovered a more unusual issue. During a previous rig works the keel stepped mast had been secured at deck level using a Spartite compound around the deck collar, rather than the original wedges, this had been incorrectly applied and had effectively bonded the mast into position to the deck.

Whilst this did not compromise the rig, it did require part of the deck to come out with the mast, necessitating fibreglass repairs to the deck collar. Thankfully, the correct skills and materials were on hand.

Preparing for the miles ahead

Individually, none of these items define a Bluewater-ready yacht. 

The value comes from considering how all the systems work together and how the demands placed upon them change when coastal passages become months and years of continuous use.

Preparing Constance wasn't about replacing everything on a 47-year-old yacht. It was about investigating beyond the obvious, upgrading where there was a genuine benefit and preventing foreseeable problems before they happened.

Every system was inspected and given the correct maintenance, servicing or upgrade to give the required operation for the required time frame. In total, over 500 hrs were dedicated to this with nearly 200 jobs completed, from re-rigging to re-leathering the wheel and replenishing the compass oil!

By spring, the major technical work was complete. But completing a refit doesn't mean a yacht is ready to cross an ocean. It is essential to shakedown all the new and serviced systems to check compatibility and correct operation.

By completing the technical work 6 months before the start of the ARC allowed the owner a full summer season for comprehensive sea trials and to become familiar with the new systems before setting off on the ARC.  

In Part 3, we'll follow Constance back onto the water as the focus shifts from technical preparation to test sailing, fine-tuning the new systems, preparing the crew and proving the boat before departure.