Repairing Jack’s Toy

Australian Sailfish 3461 Jack’s Toy was built by Brian Carroll in 2017 after our first appearance in numbers at the Inverloch Classic Wooden Dinghy Regatta (ICWDR). At every event since then Brian and Jack’s Toy have been regular competitors at or close to the top of the results sheet.

In 2022 at the ICWDR Brian was looking good for a clean sweep until there was an incident. A larger boat which was not part of the Regatta sailed through the racing fleet on port tack until it struck Jack’s Toy which was on starboard tack. This was the result:

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Jack’s Toy viewed from above, possibly the non-slip helped reduce the amount of damage. [By Lyn Wallace, Inverloch, 20 February 2022]

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Jack’s Toy side view. Side, gunwales and deck ply all smashed in, this is the photo that starts to show the true extent of the damage. [By Lyn Wallace, Inverloch, 20 February 2022]
From here, Jack’s Toy was taken back to Paynesville, insurance stuff happened and it was eventually decided that the cost of professional repairs meant it was an insurance write-off. After the insurance matters were resolved Brian was able to recover Jack’s Toy and commence work on it himself.

The deck was removed and the damaged part of the hull side and the gunwale were cut away.

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Router around the edges and off with the old deck ply. The unvarnished section in the foreground is where the non-slip has been removed. [By Brian Carroll, Paynesville, 28 May 2022]

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Port side of the deck removed, note the size of the hole top right of picture. [By Brian Carroll, Paynesville, 28 May 2022]

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All the deck removed except over the deck beam and the gunwales, damage is top right of this picture. Note the extra stringers around where the skipper sits. [By Brian Carroll, Paynesville, 28 May 2022]
With the deck removed and the side cleaned up a bit it became easier to see what needed some attention. Luckily the timber along the bottom edge where the side panel (plywood sides) and the bottom ply meet looks to be OK.

Must be time to start putting stuff back!

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Damaged side panel and gunwale cut away, butt straps fitted, ready for gluing. [By Brian Carroll, Paynesville, 5 June 2022]

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New side panel piece inserted and glued in place, excess along the top edge waiting to be trimmed to fit. [By Brian Carroll, Paynesville, 5 June 2022]

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Side panel sanded down, you can just make out the pencil line that marks where the top edge of the gunwale will be. [By Brian Carroll, Paynesville, 5 June 2022]

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Another view of the repair, this time from the inside, showing butt strap positioning. [By Brian Carroll, Paynesville, 8 June 2022]

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Gunwale added and ply faired down plus an extra stringer for added deck rigidity. [By Brian Carroll, Paynesville, 12 June 2022]
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Close up of the repair so far showing butt straps, gunwale and extra stringer detail. [By Brian Carroll, Paynesville, 12 June 2022]

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Outside view of the patch in the side and the piece cut into the gunwale, nearly ready for painting. And a new deck! [By Brian Carroll, Paynesville, 12 June 2022]
I will be adding more to this story as it progresses, so keep checking back to keep up with the progress of the Jack’s Toy repair.

Late June and Jack’s Toy is getting a refresh with a change from varnished to painted on the bottom.

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Turned over and a coat of paint going on. [By Brain Carroll, Paynesville, 25 June 2022.