The owner of this Stejcraft contacted us about a serious crack in one of the spray rails that was allowing water into the hull. As the owner was located outside our service area and unable to bring the boat in initially, we provided an estimated repair cost based on photographs supplied to us.

Once the boat arrived at our workshop and we were able to inspect it properly, we discovered the spray rail failure was actually the result of significant rot in the aft stringers and floor. With the internal structure compromised, the hull skin no longer had adequate support. Over time, repeated loading and unloading on the trailer caused the unsupported section to flex and eventually fail.

To properly repair the damage, we began by rebuilding the aft section of the hull associated with the failed spray rail. The first stage involved replacing the rotted sections of the stringers. This required supporting the hull off the trailer, relieving pressure from the damaged area, and carefully bracing the hull to restore its original shape as much as possible.

Before installing the new floor section, we rebuilt the internal section of the damaged spray rail to restore its structural integrity. For added strength and durability, we also reinforced the opposite side of the hull. A new floor section was then epoxy bonded into place over the rear of the spray rails and fully glassed over, significantly increasing overall rigidity.

As most of the structural reinforcement was completed internally, the exterior spray rail repair only required a light layer of fiberglass, followed by fairing and refinishing work to restore the original appearance.

While the boat was in for repairs, the owner also requested the addition of a built-in bait tank. This was incorporated into the port-side aft seat and constructed using composite materials to match the factory moulded lines of the boat. The flush-mounted lid featured a non-skid finish and was designed to maintain access to a new transom boarding ladder, which we also supplied and installed. The bait tank itself was fully plumbed with a through-hull pump pickup and overflow system.

Additional work completed during the project included installing a new seat opposite the bait tank, as well as carrying out several smaller repairs to the transom and hull.

To complete the spray rail refinishing work, the boat was lifted onto workshop stands. During preparation for the lift, we discovered the tow fitting was loose and appeared undersized for the application. After discussing this with the owner, we replaced the fitting with a more suitable unit.

Once the hull was supported on stands, further issues became apparent with the existing trailer. After being advised of the condition, the owner elected to replace it with a brand-new trailer. As with any new trailer setup, we adjusted the roller positions and support points to properly suit the hull before returning the boat to the trailer, ready for collection.