EP64: Anchor Chain Prep Turns Into a Full Windlass Refit
A simple plan to prep the anchor chain uncovers corrosion, rot, and a windlass that needs replacing. Real refit work aboard Roam.
What started as a simple plan to prepare the chain locker for a new anchor chain quickly turned into something much bigger. In this episode, we dig into one of the dirtiest, most confined spaces on the boat and uncover issues that force us to rethink our original plan.
EP64 is a hands-on look at what refit life actually looks like—corrosion, surprises, tough decisions, and the slow work of making things right for the long haul.
📽️ Watch Episode 64
Removing and rebuilding a windlass and chain locker aboard a cruising catamaran during a full refit.
Episode Summary
In EP64 of Sailing Roam, we set out to clean and prep the chain locker for a new anchor chain—only to discover significant corrosion, cracks, and damage in the existing windlass. What should have been routine maintenance quickly escalates into a full windlass replacement and a deeper dive into the realities of refitting a cruising catamaran.
We remove years of rust and debris from the chain locker, uncover unsealed plywood that has rotted over time, and rebuild the space using durable Coosa panels and thickened epoxy. The compartment is sanded, primed, and painted, leaving it clean, structurally sound, and ready for a new windlass installation.
This episode captures the physical challenges, problem-solving, and decision-making that come with liveaboard refit work—and why small jobs so often turn into much bigger ones.
What We Set Out to Do
The plan was straightforward: clean out the chain locker and get it ready for a brand-new anchor chain. Years of rust flakes, mud, and debris had built up, and it was time to deal with it properly.
Like many refit projects, it seemed simple—at least at first.
When the Windlass Told a Different Story
Once we started opening things up, it became clear the windlass had bigger problems. Corrosion, cracked components, and worn parts showed signs of long-term issues that weren’t going to be solved with cleaning alone.
Between the condition of the hardware and our move toward a higher-voltage electrical system, repairing the existing unit no longer made sense. The decision was made to replace it entirely and rebuild the surrounding space properly.
Cleaning Out Years of Rust and Debris
Anchor lockers are hard on boats, and ours was no exception. Most of what looked like mud was actually rust from the anchor chain itself—flakes that had accumulated over years.
We vacuumed, scraped, and sanded every surface we could reach, working in a tight, awkward space that demanded patience and more than a little contortion. It wasn’t glamorous work, but it was necessary groundwork for everything that comes next.
Rebuilding the Locker the Right Way
During cleanup, we discovered unsealed plywood that had rotted over time. Rather than patching it, we removed the damaged material and replaced it with custom-cut Coosa panels—measured for irregular, non-square spaces and bonded in place with thickened epoxy.
The goal wasn’t perfection. It was durability, longevity, and building something that wouldn’t need to be revisited again anytime soon.
Priming, Painting, and Looking Ahead
With the structure rebuilt, we sanded, primed, and prepped the locker for paint—even working around cold weather to get coatings cured properly.
The chain locker is now clean, solid, and ready for the next phase: installing the new windlass and continuing the larger systems rebuild aboard Roam.
Why This Episode Matters
EP64 is a perfect example of how refit life actually works. Small jobs rarely stay small, and the real work often starts once you see what’s hiding underneath.
If you’re interested in the bigger picture behind this work, we’re documenting the full electrical rebuild—including the decisions that led to this windlass upgrade—on our in-progress systems page here:
What’s Next
Next up, we're dealing with arctic weather and we'll share what happens when it's just too cold to go to the boat.
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