EP51 - Installing our new DIY bowsprit
After losing our bowsprit offshore in EP14, we install a custom-designed replacement—closing the loop on a hard-earned lesson.
Episode Overview
Some refit projects exist because something wore out. Others exist because something failed spectacularly.
Back in EP14, during our first multi-day offshore passage from Isla Mujeres to Biscayne Bay, our gennaker halyard failed. The result was dramatic: we lost the sail and the original bowsprit. It was one of those moments that sticks with you—and one that made it clear a replacement wasn’t just cosmetic. It had to be stronger, smarter, and better suited to how we actually sail.
In this episode, that story comes full circle as we install the new bowsprit Shawn designed and had fabricated locally in Virginia.
📺 Watch Episode 51👉
Welding and installing a custom bowsprit on a catamaran to replace one lost during an offshore passage.
From Failure to Redesign
The original bowsprit didn’t fail on it's own—it failed because something else that used it failed and caused a cascading failure - the worst kind.
This time around, the goal was clear:
- Overbuild where it matters
- Eliminate known weak points
- Create a platform that could confidently handle off-wind sails
Designing it was one challenge. Installing it was another entirely.
Installing the New Bowsprit
With the new bowsprit ready, we bring in a very talented friend to help with the installation. This isn’t a bolt-on job—it requires careful alignment, fabrication, and welding directly on the crossbeam.
The work includes:
- Welding strips to secure the trampolines properly
- Welding eyes to attach the bowsprit to the crossbeam
- Making sure everything lines up before committing
All of this happens on a brutally hot Virginia day, the kind where every step takes longer and every mistake costs more sweat than usual.
Why This Matters
The bowsprit isn’t just a piece of hardware—it’s a critical part of the sail plan.
Getting this right means:
- Safer off-wind sailing
- More confidence flying the our reaching and running sails
- Closing the loop on a failure that started far offshore
It’s one of those refit moments where progress feels earned.
In This Episode
- Revisiting the bowsprit failure from EP14
- Installing a custom-designed bowsprit
- Welding trampoline retention strips
- Welding bowsprit attachment eyes
- Working through heat, alignment, and installation challenges
What Comes Next
With the new bowsprit finally in place, we can start rebuilding confidence in our rig and sail handling. This opens the door to future rigging work and sail upgrades—without the fear of repeating past failures.
👉 If you missed it, EP14 reviews the offshore passage where this failure occured.
