EP56 – Restoring Our Sailboat’s Aluminum | Nyalic Finish & a Scary Boatyard Accident
Restoring every aluminum spar aboard Roam takes an unexpected turn when a boatyard accident sends us to the hospital — and the job still has to get finished.
Episode Overview
This episode marks the finish line on one of the biggest jobs of the refit — restoring and protecting every major aluminum component aboard Roam.
We tackled the mast, boom, crossbeam, spreaders, and davits, bringing raw, weathered aluminum back to life using professional metal prep tools and a clear coating called Nyalic. Most aluminum spars are painted or anodized, but we chose a different path — one that’s more affordable, easier to apply, and designed for long-term UV exposure.
What should have been a straightforward final push took an unexpected turn. On the day we planned to wrap up the mast, a pressure washer accident sent Shawn to the hospital for emergency surgery. The work didn’t stop — but the day unfolded very differently than planned.
📽️ Watch Episode 56👉
Refinishing aluminum spars on a cruising catamaran and dealing with an unexpected boatyard accident during a refit.
Refinishing the Aluminum Spars
Restoring the aluminum meant fully committing to the process:
- Mechanical cleaning and conditioning
- Removing oxidation and surface contamination
- Preparing each component for long-term protection
Instead of paint or anodizing, we applied Nyalic, a clear, UV-resistant coating designed to seal and protect while keeping a natural appearance.
This is not a sponsored product — we chose it because it fit our goals for durability, cost, and long-term maintenance.
The result is a clean, uniform finish that protects without hiding what the material actually is.
Why We Chose a Clear Finish
Paint looks great — until it doesn’t. Chips, scratches, and touch-ups are inevitable, especially on spars.
A clear finish like Nyalic:
- Preserves the natural aluminum look
- Avoids costly repaint cycles
- Makes future maintenance simpler
It’s a less common choice in the yachting world, but one that made sense for how we plan to use and maintain this boat.
A Boatyard Accident Changes the Day
On what was supposed to be the final day of mast work, a pressure washer accident sent Shawn to the hospital for emergency surgery to prevent infection and compartment syndrome.
It was a sobering reminder that even familiar tools can become dangerous, and that boatyards are not forgiving places when things go wrong.
The refit paused — briefly — but the work wasn’t finished.
Finishing the Job Solo
The next day, Geri returned to the boatyard alone to finish the aluminum work.
It was a long, physically and emotionally demanding day, ending just as the sun went down — but the job got done. The mast and components were fully coated, protected, and ready for the next phase of the refit.
It wasn’t how we planned to finish the project, but it was a powerful reminder of why teamwork, adaptability, and persistence matter in this life.
In This Episode
- Aluminum restoration on mast, boom, and deck hardware
- Metal conditioning and surface prep
- Applying a clear Nyalic finish
- Choosing alternatives to paint or anodizing
- A serious boatyard accident and emergency surgery
- Finishing critical work under difficult circumstances
What Comes Next
With the aluminum work complete, focus shifts back to reassembly and system integration — using the freshly restored components as the foundation for what comes next.
That momentum carries into EP57, where progress continues through rigging prep, fiberglass repairs, and plumbing work that keeps the refit moving forward.
