Rebuilding the Cascade 36 Pilothouse Sloop 2008 thru 2012
Existing chain locker was not insulated and thus was subject to sweat. This brought fresh water vapor into the boat which degraded the bulkhead. Chain locker was insulated with planking of polypropylene honeycomb glassed to the hull in 4” wide planks and glassed over. This stopped condensation due to rapid temperature change and provided a durable and strong installation to handle the chain. Damaged layer of the bulkhead was replaced with Coosaboard, a foam and glass fiber product equal in strength to plywood. Anchor chain was attached to a stainless dead end fitting.
Ceiling liner was removed, the area was smoothed down and existing glass cloth was repainted with Brightside. Wiring was upgraded. All monkey rails were sanded and varnished with Man O War. Small bin cover replaced. Panels at shoulder height were refinished in high gloss Brightside White to improve reflected light. Additional vent holes were drilled. Added threshold cover for improved access to the V-berth.
New vent holes were drilled where accessible, painted with Brightside all brightwork varnished with Man O War. Holding tank manual pump bellows replaced.
Head was completely rebuilt using factory rebuild kit, new hoses installed. New vent holes drilled to encourage ventilation. Paint and varnish were upgraded. Overhead was refurbished and repainted to improve serviceability.
Starboard Hanging Locker
The wiring and diesel heater fuel line was secured, while the paint and varnish were redone. A fire extinguisher was installed with easy access.
Like many sailboats the salon was a “Teak Cave.” All panels were dark teak plywood. To improve serviceability, and to give a more spacious feeling by improving light transfer, the insides of the house were matched in value and color to the surface and slider facings formica covering. A microwave oven was added while air circulation was improved with venting and the varnish was redone. Throughout the main salon and the house itself, the port lights were replaced with larger and screened Beckson opening ports. This ended the condensation caused by bronze ports and reduced maintenance. Whenever new ventilation holes were drilled, end-grain plywood was treated with either varnish, paint or epoxy to prevent moisture absorption. The main step into the salon was secured with a small turnbuckle and the bottom vent panel was added with quick access to the electric bilge pump.
Galley sliders were re-varnished, venting improved, bin boards removed and replaced with a finer design and the area was repainted to improve light transfer and serviceability. Painting throughout has been applied to improve the look of the boat and to show off the trim. When trim and bulkheads have the same color, value and tone, little contrast exists to show off fine joinery, thus the excellent joinery work is now highlighted throughout the boat where the paint has been upgraded. A new transducer and transducer carrier was mounted under the gas oven.
Extensive rebuilding of the window trim and surrounding panels was accomplished along with a complete paint out improving the look of the teak trim and helping light transfer. A new drip molding was fabricated and installed on the pilothouse eyebrow. Instruments were upgraded and moved inside to prevent damage from the elements. New Raymarine SD 60 depth sounder, Garmin 441 GPS chartplotter and JRC 1000 Mk II radar screen were mounted. A new Xantrex inverter/charger monitor panel was also installed. The overhead was re-coated with sound attenuation paint and color added. A pilot seat with hinged and locking foot rest was installed along with dual fire extinguishers. The trim borders of floor panels were added to stop scratching finished flat surfaces when opened. The electrical panel was reworked to simplify and improve existing circuits and fuses. Numerous circuits and wiring harnesses have been reworked and reattached using crimp lugs, tye wraps and cinch brackets. Navico PH 8000 autopilot was refurbished by Industrial Electronic Repair of North Carolina.
Two starting batteries were moved from their outside locations into the pilothouse area. This gave them a more stable environment with less temperature fluctuations. All battery cables were replaced with pressure crimp fittings and a new inverter/charger was installed. All batteries are now secured in their place. Sound attenuation fire-proof foam sheeting was installed in areas to lessen engine noise. Teflon packing has been installed in the packing gland and new zincs were installed. The boat electrical bonding system has been separated from the grounding system and bonded to the overboard inspection zinc. Keel bolts have been bonded together with the bonding system. A new Xantrex 2500 watt inverter/charger was installed with very high grade cables and hydraulic crimp lugs. Engine cover handles were installed and a new engine cover cross-member was built. A new adjustable mounting plate for the water pump was designed and installed.
The entire cockpit was repainted and Interdeck was added for safety. Storage lockers were upgraded with hanging and support devices for fenders and lines. Contact terminals were added for connecting a solar panel and a solar controller was integrated into the electrical system. Manual bilge pump cover replaced and bellows and valves were inspected.
Most of the thru deck fittings and deck cleats were removed to reduce deck penetrations. Cleats were remounted on stainless brackets attached to the very strong toe rail. This has improved the footing and safety on the fore deck. Hereshoff cleats were added and increased to 10-inch for mooring and spring lines. Ventilation and lighting were improved in the forward deck box while the windlass was refurbished and remounted on a raised platform to spread the load and improve rainwater control The teak hand rails were removed and replaced with stainless handrails which were thru bolted with lock nuts and backing boards for maximum safety. There has been a constant theme for removal or protection of varnished items in order to reduce maintenance. Now all varnished items have complete Sunbrella covers. All old paint and filler was removed from the deck and house and two coatings of epoxy was applied. Interlux primer, paint and Interdeck were applied. The main salon house and pilot house roof both have aggressive silica traction imbedded into the paint. This additional safety feature was added due to the increased height of personnel in relation to the deck and life lines.
The running rigging has been upgraded by installing a mainsheet traveler winch system to slide the traveler to the weather side during beating using a winch and jam cleats. Also, a small winch has been added to assist in furling the jib. Mainsheet tailing bag has been added to help keep the cockpit orderly. Both mainsail and 115% jib have been reworked by North Sails in Seattle.