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Catamaran Prototype Build

Starting Feb 1 – Learn How to Build High Tech from Scratch

Project Summary

The initial construction stage of the project involved building the 4 separated parts of the outer hull shell composite.  This is done on a ‘one off’ boat build by using a ‘strongback’ of cross section frames even spaced with longitudinal strips or stringers that bend into the female sections.  Core material is then formed vertically into the stringers using temporary fasteners and heat forming where necessary.  The foam is edge glued with lightweight thickened bonding epoxy for strength.  

Lamination begins on the inner exposed hull. In this case we will be using 2 layers of 7 ounce Eglass, reinforced with loadpath directionally oriented 150g unidirectional carbon fiber, and some additional thickness in areas of high foot traffic and rigging load point.  Once the inner hull side laminate is fully cured, it is removed from the ‘Strongback’ and flipped over so the outer side can be laminated.

The Outer Skin can be a bit stronger and thicker than the inside skin considering much more environmental abuse affects the exterior of the boat.  Connecting edges along the keel and deck are recessed for secondary bonding or ‘tabbing’ and fairing.  Laminate for the exterior hull is likely to be a 411 Carbon (~12 ounce) + 200 g Woven Carbon + 150g Unidirectional Carbon in specific loadpath areas.  The joined hull sides are designed to weigh a total of 250 lbs before bulkheads, fairing and paint are added to them.

The Strongback Frames are then disassembled and flipped 180 degrees to make the opposite outer side of the hull and the process is repeated.  It is possible for each hull side composite to be done in a week, making for all 4 sides able to be joined together in about 2 months.  

The tentative schedule for construction of the complete prototype.  It is likely to change as more is learned about the process.  For instance, making the first hull side shell may take much longer than the last hull side shell,  which is just one example of how the process stretched back and forth based on the learning curve and process improvements.

  • Week 1 – Making the Strongback (February 1)
  • Week 2 – Port Outer Hull
  • Week 3 – Starboard Outer Hull
  • Week 4 – Starboard Side Bulkheads
  • Week 5 – Starboard Inner Side Hull
  • Week 6 – Port Inner Side Hull
  • Week 7 – Port Side Bulkheads
  • Week 8 – Joining Hull Sides
  • Week 9 – Deck and Seat Flat Top Area
  • Week 10 – Cockpit Plinth
  • Week 11 – Cockpit Nacelle
  • Week 12 – Cockpit Edge Beams
  • Week 13 – Cockpit Core Assembly
  • Week 14 – Canopy and Canopy Covers
  • Week 15 – Hull Fairing and Finishing
  • Week 16 – Final Rigging and Commissioning (May 17, 2021)

Boatbuilding Educational Opportunity

Our tiny shop in Avon, NC has room for about 3 – 4 people to work together without tripping over each other and we do need as many hands on deck as possible to help us efficiently keep to our production objectives.  If you are interested in a hands on learning opportunity building a high performance catamaran hull prototype, there are a few educational positions open. One will learn how to go from a design to a completed boat and the lessons learned could easily be used to build your own dream boat! For those too far away to participate in person, we plan to offer an online video series featuring the production methods. Please email us to learn more.

Promotion of the Prototype Construction

Time Lapse Video – At least one camera will be dedicated and fixed to the shop wall for a time lapse video of the entire process. We will also try and put a camera on the laminating table and woodshop area, but can not guarantee those areas are filmed.

Instructional Video – We will film some of the process used and learned along the way as we build this prototype.  Emphasis will be on using manufacturer recommended and ABYC recommended Best Practices with ample explanation of our reasoning behind most choices made with the boat construction and design choices.

Website Promotion and Email Campaign – All video projects will be posted to our websites and be available on a limited basis to the general public and completely available to the general public, as long as they submit a subscription with valid name and contact information.  Specific process instructional videos may be offered on a paid subscription basis to help raise money for our materials and labor costs.

Sponsors – The pH 850 invites sponsorship and industry partners in the areas of:. 

  • Yacht Design, Naval Architecture and Engineering
  • Epoxy Resin Manufacturers and Distributors
  • Composite Fiber Manufacturers and Distributors
  • Exterior Finish and Fairing Manufacturers and Distributors
  • Sailmakers and Rigging Manufacturers
  • Composite Spar Manufacturers
  • Composite Shops Interested in Production Parts Subcontracts
  • Retail Sailboat Dealerships and Dealership Inquiries
  • Lifestyle Related Brands and Businesses
  • Rigging Hardware Manufacturers and Distributors
  • Commercial Charter Boat Industry
  • Boatbuilding Schools and Brands 
  • Any industry that promotes environmentally friendly sports and adventure

Sailmaking and Sail Repair Services in Avon

Feb 14, 2021 – Windsurfing, Kiteboard and Sailboat Sail Repair Service and more to stay on Hatteras Island.

After 10 years of incredible and meticulous sail repair service, Buxton based Wind Angel Sail Repair Service has decided its time to retire. Phillips Boatworks in Avon has acquired the commercial sewing machinery and plans to continue offering similar services to the kiteboarding, windsurfing and sailing customers on the Outer Banks and in particular Hatteras Island. Owner, Jay Phillips is an experienced sailmaker, having spent several years working under North Sails and Quantum Sailmakers in Annapolis, BVI and USVI. Other than experience, one of the important factors for quality workmanship is possession of good sewing equipment. Wind Angel’s 2 Consew 146rb Machines are top notch industrial sailmaking machines.

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Wind Angel took over sail repair business 10 years back from a couple in Avon who ran the Avon Sail House in North Avon. Now the sail repair business is returning to Avon. Phillips Boatworks is on Hwy 12 just across from the Froggy Dog, and is pretty obvious because there are frequently many boats in the yard.

Last Fall, Phillips spearheaded the new Hatteras Community Sailing Program in Avon, a non profit US SAILING based junior sailing program. Excited to have this type of machinery in the shop, one of the reasons for acquiring the machinery was to be able to support the needs of the growing sailing education and competitive programs sponsored by HatterasSailing.org. Phillips hopes that some of the kids, including his own, will take an interest in sailmaking and boatbuilding potential career possibilities. Having excellent working equipment on site makes it much easier to teach the skills.

Hatteras Community Sailing plans on offering some workshops events for its members to teach the youth sail related skills such as repair, sailmaking and sail design. Further information on Hatteras Community Sailing (Hatteras Sailing) can be found on the organizations website – hatterassailing.org

“I hope I can maintain the high standard set by Barbara at Wind Angel, and I am sure I will be calling her for advice from time to time”, says Phillips, whose experience is a bit stronger in sailboat sails, then with wind and kitesurfing products.

For more information please use our contact form in the right hand column or feel free to call or email – jay.phillips@phillipsboatworks.com 252-489-8193.

2nd Stiletto 27 Catamaran in Avon

Match Racing and Charters for Groups up to 12 passengers

Nearly mint condition 1976 Hull #3 Standard Edition

Original Owner, Meticulously Maintained, Fresh Water Sailed

We found this early model Standard Stiletto 27 in North Carolina and is an amazing example of the Stiletto 27. The Stiletto-27 is the lightest and shallowest draft, hard cockpit, trailerable catamaran ever made. Built with material conventionally reserved for aerospace and The Americas Cup, this 27 foot long x 14.5 foot wide boat collapses to 8 feet wide for trailering behind any normal car with a hitch, at only 1200 lbs. This is a special boat that comes with original documentation and paperwork from Force Engineering original signatures from the first year selling boats in 1976… almost like a time warp!

Used gently and occasionally over the years on fresh water lakes for family memories and adventure, everything on board is as you would have found it if you had purchased it yourself in 1976. This is vintage boat needs to be owned and appreciated by someone who cherishes sailing history, and still wants to have fun sailing super fast! Fully equipped, this package includes: working trailer, carbon/kevlar tape drive mainsail, original jib (in good condition), 6 hp engine, Interior and Exterior cushions, canvas, re-stitched trampoline, refurbished paint, super clean and dry interior, plus many more bits and useful pieces. Serious Inquiries only.

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Original Stiletto 27 documentation

Original Documentation of the Stiletto 27 is hard to come by, but when you have an original owner of a boat that has never changed hands otherwise it is a special and rare situation. Below are a few samples of the original documentation saved in perfect condition over the last 43 years.

Boat Inspection

Inspected by Jay Phillips, founder Stiletto-X Series

The boat was inspected and images taken on January 20, 2021

Jay Phillips, founder and developer of the Stiletto-X Series, has experience owning and refitting the Stiletto-27 models for last 30 years. Jay developed and produced the Stiletto X-Series Catamarans with a similar prepreg laminate and honeycomb core construction. There are very few boats built using prepreg honeycomb and even fewer boat surveyors who have the proper experience to evaluate these types of composites.

Stiletto-27 Inspection Report

Impeccable condition for a boat of this age, there are just a few small maintenance issues and even fewer nicks and scratches. Jay spent more than 4 hours in a detailed inspection.

  • Hull Condition – Almost perfect except for some damage to the keels from the trailer rollers being in the wrong location. The keels were repaired professionally and from I can see adequately, but it is difficult if not nearly impossible to repair a prepreg laminated hull back to new condition, so the repairs are evident on the inside of the boat hull, to the discerning eye, not so much to the average person. There are no cracks around the beam interfaces to the hull, which is common on the Stiletto 27. There are no cracks along the hull deck connection, also common on many older Stiletto 27s.
  • Canopy Cover Condition – These Lexan Canopy Covers are not original, but have been replaced with newer covers that are in excellent condition. There were some dacron straps used for lifting the covers forward that have decayed in the UV and not been replaced. It would be very inexpensive to replace with some new webbing.
  • Cockpit Stress Cracks – The Owner reported one event where the centerboard hit an underwater stump while sailing at 10 knots on the lake. The centerboard framework was bent and some damage to the cockpit laminate was incurred where the metal supports attach. It looks to be repaired on the underside, but there are some light cracks visible in this prepreg fiberglass/honeycomb front seat corner on both sides of the cockpit. This is an area where the cockpit laminates have consistently been easy to damage on several of the boats I have owned. Repairing the cracked area is not a very expensive repair, but it is recommended that it be done.
  • Deck Nonskid and Hull Paint – This boat was refinished in the late 1990s and the wear and tear on the paint in the freshwater environment the boat is in is negligible and can be polished to look like new. The deck has an evenly coated blue non-skid.
  • Mast and Standing Rigging – Original rigging. The mast has been repainted and looks like a fresh paint job even though it is several years old. All the Stainless Rigging looks to be in good condition and original. The earlier masts like this one have straight spreaders and no jumper struts, whereas later models started using swept spreaders and a jumper to reduce pumping. The rig works fine, but rotation should be tightly controlled, as the straight spreader rig is a little less forgiving.
  • Trampoline – The Trampoline looks like an original trampoline that has been restitched with Black UV tenara thread which is in good condition. The older white dacron thread is still remnant though. The trampoline is black polypropylene and still in good condition with several years of remaining useful life. Had I not been informed that the canvas and tramp been stored indoors for many of the winter seasons, I wouldnt believe it could be a 40 yr old trampoline. The owner did upgrade from original hooks on the side of the hulls to an anodized aluminum keder track, which does make installing the trampoline easier.
  • Engine – A 6 hp 2 cycle older model engine that started up immediately on first try.
  • Rudders – Fiberglass rudders of the newer stiletto design on the boat and are in pristine condition. The new fiberglass rudders like the ones on this boat are balanced better than the original mahogany rudders.
  • Centerboard – Centerboard has a few paint chips and the stainless steel framework underneath the cockpit that was damaged has been replaced and in excellent condition.
  • Beams and Tapered Pins – These show no signs of corrosion and look very clean. The holes in the beams were clean and tight. As the boats wear, the holes sometimes get larger and you notice the pins sinking in deeper, but on this boat they were still sticking out as they would have when new. (trailering the boat in the coming days and will report on how they collapse and expand.)
  • Mainsheet Traveler – This boat has an early version of the original traveler with ceramic rollers and an anodized aluminum extrusion. The anodized aluminum has some minor wear and tear but is in working condition and we have a video of the traveler rollers working.
  • Mainsail – About 20 years ago, the original mainsail was replaced with a UK Tapedrive Mylar/Carbon Scrim Sail. The sail looks to be about 10% depreciated because of its age, but barely used and in good condition. It is difficult to tell how fast the mylar laminate will last when it starts being used again, just because of the age of the laminate adhesive. It has the UK Sailmakers Kevlar Tapes which are adhered along the load paths of the sail. These types of sails are no longer manufactured, but worked and held their racing shape pretty well. UK Tapedrives were a more economical sail that competed with the North 3dl Technology of the time period. The Original Dacron Mainsail is still in pretty good condition and has been stored well. The jib is in good condition, but is an original wire luff hanked on jib.
  • Hull Interiors – Both sides were bone dry and clean. Only the keel damage repair was slightly visible under the bunks. The floorboards were near mint condition as were the pipe births. The canopy gaskets have been effective in keeping out water leaks and the Standard Edition had no port lights or deck hatches to let in water leaks.
  • Electrical System – This boat is not equipped with any electrical system that I could see. A new buyer would most likely want to install running lights, electrical panel, battery, etc., but not necessary to sail during daylight or with battery powered running lights.

Note: Phillips Boatworks has been contracted to trailer and broker the boat. As of the last week of February 2021, the boat will be located in Avon, NC for sea trial and inspection.

Serious Inquiries

    Gunboat 55 Rigging

    Leader of the Rigging Team at the Wanchese, NC Gunboat Factory. With a Team of 5 rigging team members, we worked on all stages of the rigging installations on the new Gunboat 55, all Carbon Fiber, Infused Catamaran. Nine hulls were on the floor during this time and were at all different stages of completion, from fresh out of the molds, to commissioning and launching.

    Structural Preparation for Rigging. As the hull molding process was completed on each hull, the rigging team would get to work laminating structural elements for all the rigging platforms, including: preparing winch plinth backings for hardware and laminating winch plinth into place in the cabin; installing davits backers, alinging and laminating davits into place; tech space battery, mounting surfaces, windlass chase and wire chase opening through the main bulkhead; chainplate structures; steering structures; as fabrication of many small rigging parts out of carbon fiber such as thru-deck sheaves, steering sheaves, rigging chase tubes, and redirectional roller tubes. Every padeye, chainplate, winch structural backing support and thru deck fitting.

    Parts and Parts Accessory Specification. Team leader developed a comprehensive inventory Bill of Materials for all rigging related parts and fasteners. Managing parts ordering using LEAN Manufacturing recommendations, it was necessary to reduce the amount of advanced ordering and storage of parts and convert this into a more manageable FIFO parts inventory system so parts were available for installations but not ordered too far in advance. Spreadsheet inventory counted and specified every fastener, washer and nut for all rigging on 9 boats at a time. Specification and ordering of all running and standing rigging.

    Trampoline Preparation and Installations – Gunboats have an expansive dyneema mesh trampoline that was lashed to individual eyelets on the hull and carbon longeron. The rigging team handled aligning the eyelets, installing compression tubes for each eyelet fastener and ensuring that the lightweight carbon hull shell was not compromised in any way by the highly loaded trampoline installation. Integral to the foredeck rigging was the longeron installation. Rigging, fabricated the carbon plate longeron mounting pin assembly and installed/tabbed it into the bridgedeck. Highly loaded padeyes and chainplates for the longeron side stays, whisker stays, and martingale stays were installed, then the Hall Spars, autoclaved carbon longerons were installed and held in place with a temporary dolphin striker assembly while the trampoline sections were stretched, measured and trimmed for installation. 3 mm dyneema lashings were loaded to 400 lbs on each lashing point to a bolt rope stitched into the edge of the dynemme net. Each trampoline required 3 re-stringing efforts as the net and dyneema would initially creep.

    Rig Preparation and Stepping – Rigging team installed all sensors and mast hardware on the Hall Spar Carbon Rigs. Setting diamond stay tension to about 3″ of prebend in the mast before stepping with crane service assistance. All new halyards were spliced and prepared, then installed into the rig. All new wiring for electronics and radar were installed. Mast butts were cut to fit the mast step. Mast step hardware and compression tubes under the mast step were installed by the rigging team. Booms were rigged to have a single 15mm dyneema mainsheet attached to a 9 foot hydraulic piston inside the boom. Sail packs and lazy jacks were all installed by the rigging team. All sails and roller furling installations were done by the rigging team.

    Winch Plinth Rigging – The control console inside the Gunboat 55 was designed with all lines and sheets run to 2 hydraulic harken 65 3 speed winches, and occasisionally to lewmar winches. Installation of the very complex winch hydraulic system and 16 high load halyards, sheets, tack lines, and furling lines had to run through the decks and bulkheads to the winch plinth. Designers had not yet figured out a mast base routing system for all the lines. Initial attempts by the design team were shattered by high loads on initial prototype sea trials. Team leader designed and mocked up the first working solution for a custom mast step turning block system that all 16 lines could run fairly to their hardware controls. Final specs for this $6000 custom stainless steel 16 sheave box was done by the design engineers, while all angles and routing planes were designed by the Rigging Team Leader.

    Sailing and Sea Trials – Rigging Team Leader was responsible for being on the sea trial team for the first 4 boats produced before the company went into ch7 bankruptcy. With North Sails, Hall Spars, and Design Team members, we sea trialed and tested all aspects of the boats. Rigging Team members were also on board for customer sea trials on the early boats in case anything was amiss needing rapid repair. On Asymmetrical runs, Capt Jay was able to helm the boat to 24 knots with one hull out of the water. Steering design was a constant problem and was a constant part of the rigging team leaders responsibility to troubleshoot and offer recommendation and do trial and error mitigation.

    Yacht Management

    Charter Yacht Management

    Charter Management. There are many solid reasons why offering your yacht for charter is a great idea. The safest method is to have the Charter Manager market and book your boat for you and run it as a crewed yacht. There are Bareboat situations that also work when the customers are highly screened and qualified to operate the vessel, but the boat maintenance increases, albeit offset by the income quite a bit. It is akin to Resort Property Management, which is the largest industry sector on the Outer Banks. Like private homes, the boats get used and have normal wear and tear from renters, and the management company takes care of managing the bookings, maintenance, and marketing of the asset. Its extremely important to have realistic expectations when offering your boat for charter. We like to spend alot of time working with you to discuss and describe the process, outlining the pros and cons. I personally have all my boats in charter, because I know how to take care of them and really can only afford them if the charter revenues offset the expenses, and am a big proponent!

    Private Yacht Management

    Yacht Management usually means taking care of the details so the boat owner can spend less time fixing and maintaining, and more quality time on the water with family and friends. For some, time off is extremely limited, but they still desire and pride themselves on being the boat owner. Frequently the boat can not be conveniently kept near where you live, and still be easily accessible to your favorite cruising area. Finding someone you trust to manage the care and maintenance details can be vital. Not unlike aircraft, which are extremely important to keep in perfect working condition, yachts also need to be used and operated on a regular basis to ensure the systems are at the top of their game. Even if the boat is in front of your porch window at its mooring/dock, it is still time consuming to take care of the details of proper upkeep. It takes time to establish good trustworthy relationships with your contractors and can be a hit or miss situation with many. Frequently a yacht management professional has pre-established and ongoing relationships with the various specialists needed to take of the yachts systems, and with smaller boats, just having someone keep an eye on things when you are away, is extremely important. Phillips Boatworks, offers yacht care and management services on Hatteras Island and Ocracoke.

    Should I charter my yacht?

    If you can accept that the boat will be used more often and understand that boats frequently run better if not left at rest for long periods of time, you have a good start. If you would like to earn some money to offset your boating habit, then it is a great idea. If you expect that a yacht in charter will earn a profit, you may not be thinking realistically, but you do need to look closely at how you define a profit. If you think that there will not be additional wear and tear, then you need some self calibration as well. There are tradeoffs for everything and earning money back on your boat, or running your boat as a business can have great benefits, if you can accept the reasonable tradeoffs.

    Benefits of yacht charter

    There are wonderful benefits to having your boat work as a business. The P/L of this sort of business depends significantly on how active you desire the boat to be in charter, which is directly inversely proportional to how much time it is available for your personal use. Your personal income and tax situation can have interesting benefits, if the boat is in a corporation and run as an asset in a charter business, including large tax deductions for depreciation and operating expenses.

    • Makes Boat More Affordable
    • Unlimited Owner Use
    • Customers Managed by Us
    • Commercial Use makes the boat more Seaworthy
    • Maintenance becomes a high priority
    • Possible Tax Advantages
    • Boat Kept at a Great Cruising Destination
    • Tradeoff – More wear and tear
    • Tradeoff – Trusting someone else with your boat
    • Tradeoff – Boats can get damaged
    • Tradeoff – Bookings have to be honored by the Boat Owner

    Benefits of private yacht management

    A Yacht Manager can take care of as much or as little of the boat as you desire, or want to pay for. It is an in depth discussion you must have with us before we will take on a Yacht Management Client. 40 years of involvement in the Charter Management and Private Yacht Management Industry gives us a knowledgeable basis for expectations to be setup as a win win situation for you with Phillips Boatworks.

    • Hectic Lives make for neglected boats
    • Professional Care Standards are high!
    • Manager offers experience and smart feedback
    • More time boating, less time fixing
    • Boat usually is kept beautiful and ready for you
    • Safety systems may decrease your insurance costs

    Yacht Refit

    Yacht Refurbishment Services

    Does your sailboat, motoryacht, or powerboat need maintenance attention or possibly a complete refit? Located on Hatteras Island on the North Carolina Outer Banks, where there is a tradition of boatbuilding for those who want to be shored up a few miles from where the Gulf Stream scrapes the closest point of land on the Eastern Seaboard, one refit and maintenance service truly stands out. Phillips Boatworks is owned by Capt. Jay Phillips, who has experience is all aspects of the pleasure and luxury yacht business. For big projects we have a team of designers, engineers, and boatbuilding experts that can ensure your project is handled meticulously.

    Experience with big Boatbuilding Programs! Phillips Boatworks Team is well acquainted with big projects. Owner, Jay Phillips, has been a key player at the highest quality levels of yacht manufacturing. We have built boats that stand out far ahead of the crowd at events like the Annapolis Boat Show, in that they are engineered and constructed using the most advanced composite technology currently available. Use of Prepreg Systems, Resin Infusion, Vacuum Bag and Autoclaved parts are the norm for us because the boats we have designed and engineered must be the lightest and strongest in the marketplace. This trickles down to an outstanding level of quality on all levels of fiberglass and refinishing work, even if it requires hand laid fiber and resin. We have operated, transported and worked on yachts from 100′ in length and under. We have designed and engineered some of the lightest and fastest catamarans ever known.

    Systems Engineering and Installations. While our experience with hull and superstructure is strong, so is our knowledge of how to integrate, install, repair, and maintain vital on board systems. From the diesel powerplant to the drivetrain, tankage, plumbing, bilge systems, electrical/electronics tech, and hvac systems, we have done it before a variety of yachts that we have owned, managed and maintained for others. Brands we like working with in particular include:

    Custom Boat Building

    Custom boat building on Hatteras Island

    Founder of Phillips Boatworks, Jay Phillips, has been involved in new boat builds for near 40 years. He made his first small wooden boat at age 14. Same year he started earning money working at the local boat yard, repairing and refitting all types of yachts. His first big project was a 65 ft Fishing Trawler. Later he fell in love with light weight composite multihulls, and started greatly improving his composites experience learning advanced vacuum bagging techniques as well and alongside quality woodwork and yacht joinery. He started his own production company in 2014 and developed the new Stiletto X Series of Prepreg Honeycomb performance trailerable catamarans. Currently he is starting a next generation of the Stiletto X, but slightly smaller 28 foot pH-850 Catamaran made from foam core and prepreg, for strength and weight standards normally reserved for Americas Cup quality construction. Phillips has mastered hull and part design using Rhino3d CAD Systems. If you have a boat you want designed and built. Jay can bring together the talent and team to make it happen. With all his designs, he reaches out to past team members, composite engineers, and naval architect with specialty engineering areas to make sure there is no guesswork involved and no money wasted. When Jay gets involved with your new yacht build project, you get a team effort!

    Boat Building Projects

    • Catamaran Prototype Build
      Starting Feb 1 – Learn How to Build High Tech from Scratch Project Summary The initial construction stage of the project involved building the 4 separated parts of the outer hull shell composite.  This is done on a ‘one off’ boat build by using a ‘strongback’ of cross section frames even spaced with longitudinal strips […]
    • Gunboat 55 Rigging
      Leader of the Rigging Team at the Wanchese, NC Gunboat Factory. With a Team of 5 rigging team members, we worked on all stages of the rigging installations on the new Gunboat 55, all Carbon Fiber, Infused Catamaran. Nine hulls were on the floor during this time and were at all different stages of completion, […]
    • Prototype Started! – pH 850 Catamaran
      Designer and Developer
    • Generator Installation
      Onan 13.5 kw Installation

    Sailboat Rigging

    Yacht Rigging Services

    Rigging is our specialty. Years working as a Sailmaker for Quantum and North Sails, it was necessary to get accustomed to completely retuning the rigs for new sails and racing conditions. Hired by Gunboat International in NC to be the Rigging Team Leader of the Gunboat 55 Production, Jay had the opportunity to work with some of the nicest and most expensive carbon fiber rigging products on the market. Experienced with Rigging layout and design, Jay actually solved one of the most challenging conundrums on the Gunboat 55 with a custom designed mast base block system that diverted 4 rows of highly loaded halyards, furling, and other control lines to their endpoints on the winch plinth. If you are looking for basic alloy rigging repairs, mast repairs, electronics sensor installations, or complete rigging redesigns, we have the background and experience to do it to the highest standards.

    Sailboat Rigging Installations

    • Anchor Windlass Installations
    • New Roller Furling and Roller Reefing
    • Custom Canvas Stack Pack and Lazy Jacks
    • New Mast Lights, Spreader Lights, Antennas, Radar Domes
    • New Dyneema Halyards, Sheets, Control Lines
    • Replace all your knots with spliced lines
    • Custom Wood and Carbon Spars
    • Autopilot Systems and Controls
    • Steering System Replacement and Repair
    • Stronger and Lighter Fiber Rigging Solutions
    • Code 0 Asymmetrical Top Down Furling
    • Multihull Trampolines and Lashing Systems
    • Spinnaker Dousing Socks

    Sailboat Rigging Repairs

    • Yearly Winch and Windlass Cleaning and Service
    • Headsail Furling System Troubleshooting and Repair
    • Bent/Broken Mast Repairs, Spreader Repairs
    • Spar and Rigging Inspections
    • Custom Running Rigging and Splicing
    • Canvas and Sail Repair
    • Mast Sensor Troubleshooting
    • Masthead Light Replacements
    • Steering System Maintenance
    • Steel and Fiber Rigging Repair
    • Trampoline Net Repair and Replacement

    Is Fiber Rigging right for my boat?

    One of the main reasons for fiber rigging is to reduce weight aloft by replacing heavy alloy rigging with the substantially lighter fiber/composite rigging. This reduces a sailboat’s pitching and healing moment. If you are competitive on your sailboat and not restricted by any racing rules or rating penalties for having fiber rigging then it is a great option to enhance the performance of your sailing. Note though that a big expense like this should be accompanied with other weight saving efforts on the boat. If you are going to spend $10k on the rigging replacement but have the heaviest sails, and store full tanks of fuel, water, and blackwater and have granite countertops in your galley, its kind of pointless. To enhance the your boats performance, weight has to also be taken out of the ends of the boat (bow and stern), all cabinets emptied for racing, tanks drained to the bare minimum, have a ceiling on weight of crew gear on board, etc. etc. etc. Its this kind of meticulous counting of the weight on board that starts making a difference in the performance when coupled with high end rigging replacements. Frequently even while sailing a close race with another boat, it helps even to have latent crew sit below as close to the keel as possible. Crew kinetics are extremely important to maximize your boat speed and reduce the drag in the ends of the boat.

    Alternatively, with multihulls like the Stiletto or even the Gunboat, some fiber rigging choices make handling the rigging simpler. With the advent of affordable high tech materials like Dyneema, the performance boats have been reversing the heavy turnbuckle trend more in favor of lighter weight shroud lashings, high strength dyneema loops, high friction rings instead of blocks, and more. We use Dyneema SK99 on our 27 foot catamaran for shrouds and stays because its easy to work with on and off the boat with ample working load capabilities at the correct diameter.

    Marine electronics

    Marine electronics installation and repairs

    Phillips Boatworks is experienced with Raymarine and Garmin Installations for Power and Sailing Yachts. If you just need a dependable chart plotter or extensive new electronics and communications network on your yacht, please give us a call. As a highly experienced captain, Jay Phillips understands how important it is to have reliable navigation and communications while you are offshore and possibly in the worst imaginable weather conditions.

    Marine electronics services

    • Chartplotter and Radar Installations
    • Performance Sailing Electronics
    • Yacht Monitoring and Tracking Systems
    • Custom Electrical Refits and Systems Monitoring
    • Tank Monitoring
    • EPIRB and AIS Systems for Safety
    • VHF, SSB, Satellite Communications

    Hire a captain

    How should you find a captain to move your boat?

    Originally licensed in 1992 to run his first Catamaran Daysail Charter Business, Captain Jay has made all aspects of sailing his life’s passion. He has operated and managed all sizes, kinds and types of boats, from 97′ Browards, to 85′ Luxury Charter Catamarans, Harbor Tour Boats in downtown Annapolis and even Sport Fishing Charters from Marco Island in the Bahamas and Florida Keys. As an Owner of a Yacht Charter Management Company, Phillips learned even more how hard it was to find competent Captains that understood, not only how to safely operate boats, but manage their ongoing maintenance along the way. Currently as a Boat Builder and Designer, Jay is keen on full understanding of the boats he operates. If you want your yacht successfully and competently managed, operated, chartered, or delivered–you will be hard pressed to find anyone more capable and experienced. Jay is a great navigator and sailor with years of solo ocean deliveries under his belt and probably close to 200,000 logged sea miles. Whether it is an Offshore Carbon Fiber Racing boat, or a Commercial Shrimper, or a Luxury Megayacht with 10 crew to manage, Capt. Jay can handle it.

    Yacht Delivery

    Full time captain