Welcome aboard the Youngbarnacles Composites Hub!

This is the home base for our mission to refit Paikea and document the process for everyone. We’re peeling back the fiberglass to show you what goes into a proper boat refit, sharing the good, the bad, and the messy.

Our focus is on demystifying composite materials—the fiberglass, carbon fiber, and resins that make modern boats strong and light. Whether you’re a DIYer or a fellow sailor, we’re building this resource to give you the practical knowledge you need to work confidently on your own projects or simply understand the structure beneath your feet.

Dive into our project logs and guides below. Let’s learn together.

Ready to go further? The Youngbarnacles Membership unlocks access to detailed video tutorials, downloadable files (like 3D print files for our Composite Stanchion Socket Drain), and direct access to our community forum to share ideas and gather intel from like minded sailors and composite enthusiasts. Explore Membership Benefits.

Technical Library & Industry Links

A curated collection of technical articles, product specifications, and links to specialist suppliers and manufacturers we use and trust. This library serves as a reference for the materials, components, and engineering principles we apply in our own projects.

Websites

• World Sailing https://www.sailing.org
• C-Tech Sail Battens: sailbattens.com

In our design considerations for Stanchion Sockets build we referr to the following rules governing Marine Design:

• World Sailing Offshore Special Regulations (OSR): Provides the benchmark for offshore racing safety.
• ISO – Standards ISO 15085:2024(en) Small craft Protection from falling overboard and means of reboarding
• ABYC H-41 REBOARDING MEANS, LADDERS,HANDHOLDS, RAILS AND LIFELINES

Download Technical Articles

An analysis of why nylon peel ply can introduce contamination and weak bonds, and why polypropylene is the superior choice for a guaranteed structural surface.

An engineering analysis on the application of carbon fibre for pulpits and stanchions. This paper evaluates the trade-offs between weight savings and impact resistance, focusing on failure modes and practical considerations for offshore use.

CESR POLICY REVIEW. Special Regulations Interpretation 6. Limitations on Stanchion Materials.

Working with Composites on Paikea

A practical archive of composite applications from the refit of our Catana 42. This log documents the real-world use of materials and techniques—from rudder construction to bulkhead reinforcement—providing a grounded reference for your own projects.

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  Solving Boat Shower Drainage with Cardboard, CAD, 3D Scanning & 3D Printing
  The Hybrid Design Workflow: Building a Boat Shower Floor with Cardboard, CAD, and 3D Scanning: Walk through the hybrid design process for a custom boat shower floor. See how cardboard prototyping, CAD, 3D scanning, and… Read more: Solving Boat Shower Drainage with Cardboard, CAD, 3D Scanning & 3D Printing
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  The Boat Shower Floor Blueprint: Drainage, Hatches & Avoiding Bilge Floods
  When your floor needs to drain, provide access, and never flood the bilge. A deep dive into the logic behind our custom shower hatch. Key Topic: Join Shayne & Anna in the bilges for a… Read more: The Boat Shower Floor Blueprint: Drainage, Hatches & Avoiding Bilge Floods
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  Boat Hatch Build: Installing Lenses & Drains for a Watertight Finish
  Key Topic: After months of building custom composite hatches, we reach the transformative stage: making them watertight and bringing in light. This hands-on guide walks you through our exact process of installing thick acrylic lenses,… Read more: Boat Hatch Build: Installing Lenses & Drains for a Watertight Finish
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  Diagnosing and Repairing Hull Delamination and Core Damage.
  The Problem: From Floor Installation to Structural Repair Author: Shayne and Anna During the installation of new cabin soles in our Catana 42 refit, a routine task uncovered a significant structural issue. The discovery process… Read more: Diagnosing and Repairing Hull Delamination and Core Damage.
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  The Professional’s Approach: Replacing a Problematic Hatch with a Proven Structural Portlight
  Topic Overview: We permanently eliminate a chronic leak point and increase deck panel strength by removing a problematic overhead hatch and glassing in a solid, camber-matched core. In its place, we install a robust, under-gunwale structural… Read more: The Professional’s Approach: Replacing a Problematic Hatch with a Proven Structural Portlight
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  Bulkhead Reinforcement on a Catamaran: Beam Theory Explained
  Bulkhead Reinforcement on a Performance Catamaran Why Beam Theory Matters More Than “More Fibreglass” During refits, bulkheads often get treated as simple partitions—something to hang doors off or separate spaces. On a performance multihull, that… Read more: Bulkhead Reinforcement on a Catamaran: Beam Theory Explained
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  Prioritising Solar Over Shore Power: A Victron Setup for Marina Life
  Author: Shayne and Anna Key Message: Living aboard in a marina doesn’t mean you’re tied to the shore power pedestal. This post details how we reconfigured our Victron MultiPlus inverter/charger on our catamaran Paikea to prioritize our solar… Read more: Prioritising Solar Over Shore Power: A Victron Setup for Marina Life
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  The Not-so-Glamorous Work of a Boat Refit: Fairing, Filling, and Fixing Leaks
  Key Message: A professional finish is 90% preparation. The glamour of a new paint job is entirely dependent on the meticulous, unglamorous work of surface preparation and problem-solving that happens first. Author: Anna and Shayne Introduction On… Read more: The Not-so-Glamorous Work of a Boat Refit: Fairing, Filling, and Fixing Leaks
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  Hull Weight Reduction & Flush Hatch Installation: Paikea Refit Update
  Key Message: Significant weight reduction is not just about going faster; it’s about returning a performance multihull to its designed potential, which requires a systematic, professional approach to refitting. Author: Anna and Shayne Introduction This refit update… Read more: Hull Weight Reduction & Flush Hatch Installation: Paikea Refit Update
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  Professional Hatch Installation: Solving Leaks with Precision Engineering
  Key Message:  This post documents two distinct professional upgrades on our Catana 42 refit: the precise installation of custom composite deck hatches and the full conversion of leaky portlights to watertight, outward-opening hatches. The first… Read more: Professional Hatch Installation: Solving Leaks with Precision Engineering
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  Building Composite Hatches Using 3D Printed Molds
  Key Message: Precise, Accessible Fabrication with 3D Printed ToolingBuilding custom composite hatches requires tooling that can accurately capture complex geometry. This project demonstrates a practical approach: using 3D printed molds for both the hatch lid… Read more: Building Composite Hatches Using 3D Printed Molds
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  Engineering Custom Composite Hatches: A Systematic Approach
  Topic: A detailed breakdown of the design and engineering process for creating custom composite deck hatches, covering problem analysis, material selection, structural integration, and the use of 3D printing for prototyping and manufacturing. Author: Shayne and Anna… Read more: Engineering Custom Composite Hatches: A Systematic Approach
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  Building Lightweight Composite Shelves for Our Catamaran
  Solving the Boat Storage Puzzle: Strong, Custom & Lightweight Shelves One of the eternal challenges of living on a boat is creating functional storage without adding unnecessary weight. Every kilogram counts, and every millimeter of… Read more: Building Lightweight Composite Shelves for Our Catamaran
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  Composites the Hard Way: Fixing a Vacuum Infusion Implosion
  Author: Shayne and Anna Key Message: A dramatic vacuum infusion implosion taught us that in composite boat building, true expertise isn’t about avoiding failure—it’s about mastering the art of the recovery. By diagnosing the precise physics of… Read more: Composites the Hard Way: Fixing a Vacuum Infusion Implosion
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  Laminating Stanchion Sockets & The Truth About Peel Ply
  Key Message: A successful composite lamination is defined by understanding the loads, mastering the process, and knowing the hidden details—like why you must always sand a peel ply surface before secondary bonding. Author: Shayne and Anna… Read more: Laminating Stanchion Sockets & The Truth About Peel Ply
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  From Scrap Foam to Flying: Building a Custom Pump Foil Board
  Key Message: Even with professional knowledge, hands-on projects are a process of problem-solving. The goal is a functional, lightweight part, and sometimes that means making—and fixing—mistakes along the way. Author: Anna & Olly Introduction This project… Read more: From Scrap Foam to Flying: Building a Custom Pump Foil Board
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  Engineering Lighter, Smarter: Why We’re Replacing Paikea’s Wooden Doors with Composites
  Beyond the Slam: Engineering Composite Doors for a Performance Catamaran Author: Shayne & Anna Key Message: The choice of material is never about what’s “best,” but what is most fit for purpose. For our performance refit,… Read more: Engineering Lighter, Smarter: Why We’re Replacing Paikea’s Wooden Doors with Composites
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  Engineering a Lightweight Door: The Value of 350 Grams
  Topics: A detailed look at the design and fabrication of a structurally efficient composite door, highlighting the techniques for managing complex geometry and the performance philosophy that values incremental weight savings. Author: Shayne & Anna In the… Read more: Engineering a Lightweight Door: The Value of 350 Grams
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  Re-Engineering a Structural Bulkhead | Cutting a Doorway Adjacent to a Carbon Chainplate
  Author: Shayne and Anna Key Message: Major structural changes require professional composite engineering expertise. This project demonstrates what is possible but should not be attempted without a deep understanding of load paths and advanced laminating techniques. Introduction… Read more: Re-Engineering a Structural Bulkhead | Cutting a Doorway Adjacent to a Carbon Chainplate
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  Making Composite Stanchion Sockets: An Engineering Approach to Safety & Aesthetics
  Key Message: A successful upgrade to a critical safety system requires understanding not just how to build it, but why you choose specific materials and processes. The goal is a solution that is stronger, cleaner, and fails in… Read more: Making Composite Stanchion Sockets: An Engineering Approach to Safety & Aesthetics
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  Staunchion Sockets: A Masterclass in Material Selection and Failure Modes
  Key Message: Choosing materials isn’t about what’s “strongest,” but about how they handle loads and, just as importantly, how they fail. A pultruded carbon spiggot might seem high-tech, but its failure mode makes it a dangerously… Read more: Staunchion Sockets: A Masterclass in Material Selection and Failure Modes
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  Hand Lamination vs. Vacuum Infusion: A Practical Weight & Quality Comparison
  Hand Lamination vs. Vacuum Infusion: The Real-World Trade-Offs Author: Shayne Key Message: The choice between hand lamination and vacuum infusion isn’t about which is “better,” but what you need from the finished part. For weight-critical applications… Read more: Hand Lamination vs. Vacuum Infusion: A Practical Weight & Quality Comparison
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  Engineering a Crash Box: Protecting Paikea from a Daggerboard Failure
  Engineering a Crash Box: Proactive Safety for a Daggerboard Strike Author: Shayne Key Message: True safety in yacht design isn’t just about strong parts; it’s about planning for failure. A watertight crash box is a passive… Read more: Engineering a Crash Box: Protecting Paikea from a Daggerboard Failure
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  Re-Engineering a Hull: Load Paths, Daggerboards, and a New Structural Bulkhead
  Author: Shayne and Anna Key Message: The most important part of a structural refit is understanding and optimizing load paths. By relocating a bulkhead to align with the strongest part of the daggerboard foil, we significantly… Read more: Re-Engineering a Hull: Load Paths, Daggerboards, and a New Structural Bulkhead
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  Refit Progress: Templating, Infusing, and Building a New Laminating Table
  Key Message: A major refit is a series of small, repetitive, and precise steps. By creating a family “assembly line” for templating and infusion, we’re efficiently producing lightweight, custom composite floors while constantly improving our workshop… Read more: Refit Progress: Templating, Infusing, and Building a New Laminating Table