Sunfish Restoration Project

BG3

Member
My father bought a 1980 Sunfish without really doing his homework. Right off the bat, we had to order a new rudder assembly as the previous owner had removed the original gudgeon bracket and mounted a homemade adapter for a flimsy rudder I've never seen before. We also upgraded all the lines and installed an outhaul and cunningham.

After taking on a bunch of water during the first sail early this spring, we realized he bought a project. Well, we started working on Father's day and I've been working on it since. The further I got into it, the more issues I found. The deck was completely separated from the hull at the bow. Also, a hole in the bow. There were over 20 places along the hull/deck joint that leaked and had to be epoxied. The other issues are pretty apparent from the before pics.

We've still got a few final tasks like installing the rail trim and polishing. Though, Dad was finally able to sail her this past weekend. First time sailing with my father since we raced PHRF over 16 years ago.

Here's a few pics of the project before:
 

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These are after a ton of epoxy and gelcoat work was finished. I then sanded the entire hull with 80 grit and cleaned with Interlux Fiberglass Wash to remove all wax from the gelcoat process.

I reconstructed and reshaped the ends of the splash guard. Had to seal the joint between the cockpit and deck along the entire starboard side as it was never sealed.
 

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After painting with four coats of VC Performance Epoxy and wet sanding with 320 grit, 400 and 800. We kept on with 1000, 1500 and finished with 2000. This is the hardest coating I've ever dealt with that wasn't DLC or Kashima.
 

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Re-painting the original brown and orange stripes and splash guard.
 

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The finished project. We capped it off with a new replica FRP daggerboard from Intensity to replace the wood daggerboard that wasn't correctly sized and in bad shape.
 

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Dad enjoying his restored Sunfish for the first time. We sailed almost twelve miles. Great day.
 

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Forgot about the hiking strap install.
 

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