Wooden Mast RESTORATION: pRECISION rEPAIRS TO cOLUMBIA'S 150' tOPmAST
Restoring a classic wooden mast is no small feat—especially when it weighs over 11,000 pounds and belongs to a historic sailing yacht like Columbia. At Portland Yacht Services (PYS), our expert team recently completed one of the most technically demanding wooden spar repairs in recent memory: restoring the 150-foot foremast and topmast of this iconic vessel.
Why Wooden Masts Require Specialized Care
Wooden spars offer unmatched aesthetics and traditional appeal, but they also demand meticulous maintenance and repair. Unlike modern aluminum or carbon fiber masts, wooden masts are susceptible to moisture imbalance, rot, and internal checking—especially when exposed to uneven heat during winter storage. That’s why PYS prioritizes moisture control and careful material handling during every stage of the restoration.
From Unstepping to Inspection: A Full-Scale Mast Rehabilitation
The restoration plan began in late 2024 with the unstepping of Columbia’s towering foremast. Once safely brought down, the mast was moved into our heated storage facility, where radiant floors keep a steady 68°F—ideal for both off-season boat storage and detailed woodworking. However, that consistent warmth also presents challenges: dry air can cause moisture imbalances in wood. To prevent checking and cracking, we maintained ideal moisture levels (~12%) by hydrating the mast with soaked moving blankets each night.
Discovering Rot and Planning the Repair
During inspection, our team discovered significant rot at the butt-end of the topmast. This critical area, where the topmast joins the foremast using pins and collars, had nearly 36 inches of compromised wood on its aft half. Repairing this damage required routing out and replacing five large sections—up to 9 feet long each—while preserving the original hollow lay-up pattern of the mast.
Complex Techniques: Birdsmouth Joints, Scarfing, and Epoxy Bonding
Repairing a hollow wooden mast demands advanced joinery. Each section was carefully routed out using a sled-guided router, then replaced with a matching plank featuring birdsmouth joints for structural integrity. We used G-Flex epoxy for its toughened, flexible bond and ratchet straps as clamps to ensure precise alignment during curing.
With over half the circumference of the bottom 9 feet of the mast replaced, our final step was reshaping the repair area. Using hand planes, we brought the new wood back to round, then sanded, primed, and refinished the entire section for a seamless match with the rest of the spar.
Extra Protection: G-10 Sleeves to Prevent Future Rot
As an added upgrade, we installed G-10 fiberglass sleeves in every bolt hole to prevent end-grain rot—a common failure point in wooden masts. This long-lasting solution helps ensure the longevity of the repair and provides a barrier against moisture intrusion in high-stress connection points.
A One-of-a-Kind Project That Showcases What PYS Can Do
From lifting a mast that spans half a football field to managing millimeter-perfect wooden repairs, this project demanded collaboration, experience, and capability. Our rigging crew, woodworkers, and project leads worked in sync to achieve what few yards in the country can do. This repair wasn't just maintenance—it was preservation of a legacy.
As the Columbia now sails again with her stunning spars restored, we reflect proudly on the craftsmanship and care that went into what we affectionately call “back surgery on an elephant.” At Portland Yacht Services, we’re honored to be one of the few marine facilities trusted with work of this scale and significance.
-John Guilliams
Wood Shop Manager
Now that spring is in full swing and summer is just around the corner, Maine boaters are already hitting the water—or getting ready to. Whether you're cruising the coast, casting a line, or towing the family for water sports, making sure your power boat is properly prepped can mean the difference between a great day on the water and an unexpected delay. At the Outboard Shop, we’ve compiled a list of essential pre-season tips to help you get your vessel out of storage and back on the water with confidence. 1. Begin with a Thorough Inspection Start with a walkaround of your boat. Check the hull for cracks, dings, or signs of wear. Make sure all fittings are tight and nothing looks out of place. If you use a trailer, inspect the tires for dry rot, ensure the lights are working, and test the brakes if applicable. 2. Charge and Test the Battery Batteries tend to lose charge in storage. Fully charge your battery and clean the terminals to prevent corrosion. Check the voltage and, if your battery is more than a few years old, consider testing or replacing it before heading out. 3. Flush and Inspect the Engine Your outboard motor is the heart of your vessel. Flush the engine with fresh water, inspect the fuel lines, and replace any brittle or cracked hoses. Change the oil and gear lube, and inspect the impeller and cooling system. Old fuel? Drain it and refill with fresh gas for optimal performance. 4. Propeller & Control Systems Remove the propeller and look for dings, cracks, or tangled fishing line. Grease the shaft before reinstalling. Also check your steering and throttle systems for corrosion, stiffness, or wear—lubricate and adjust as needed to ensure smooth operation. 5. Check the Fuel System If you didn’t use a stabilizer before winter, you may need to drain the fuel tank and replace it with fresh gas. Don’t forget to inspect and replace the fuel filter and fuel lines if they show signs of age. 6. Test All Electrical Systems Power up your electronics: GPS, radio, depth finder, and lights. Make sure all bulbs and fuses are working. Most importantly, test your bilge pump and float switch. Pour water into the bilge and confirm that the pump activates and drains properly. Also, test your bilge blower (for inboards), horn, and navigation lights. 7. Clean and Prep the Bilge Make sure the bilge area is clean and free of debris that could clog the bilge pump. This is a critical safety step that many overlook. 8. Verify Thru-Hull Fittings Inspect all thru-hulls for cracks, discoloration, or looseness. These fittings are vital to your boat’s integrity—replace any that show signs of failure. 9. Review and Refresh Safety Gear Ensure your life jackets are in good condition and Coast Guard-approved for your passenger count. Check the fire extinguisher’s charge and expiration date, confirm your signaling devices (flares, horn, whistle) are working, and restock your first aid kit. 10. Clean, Wax & Restock Give your boat a full cleaning—inside and out. Wash away mildew and grime, and apply a coat of wax to protect the finish from UV rays. Check cushions and upholstery for mold, and restock any supplies you typically carry onboard. 11. Don’t Forget the Drain Plug It may sound simple, but one of the most common and costly mistakes is launching without the garboard drain plug installed. Know where it is—and double-check that it’s installed before you hit the ramp. 12. Book a Professional Tune-Up When in doubt, bring your boat in for a spring service. At the Outboard Shop, our technicians can perform a full-season tune-up to ensure your engine, systems, and safety equipment are ready for whatever the season brings. Bonus Tip: Keep a maintenance log. Not only does it help you stay on top of seasonal service, but it also adds value when it’s time to sell or trade in your boat. Getting your power boat ready doesn’t have to be complicated—especially when you follow a checklist and get expert advice along the way. From battery checks to bilge pumps and everything in between, the Outboard Shop team is here to help you launch your season right. See you on the water! – Steve Nichols, Outboard Shop Manager
From March 30 to April 6, 2025, Nanny Cay Marina hosted the 52nd edition of the BVI Spring Regatta. A premier sailing event that draws competitors from around the globe. Among the participants were Brent Sullivan and Rob Windsor, representing Portland Ship Yard aboard the high-performance catamaran, Timbalero 3. Sailing in the Performance Multihull category, their journey exemplified resilience and the enduring spirit of competitive sailing, while achieving speeds, 30 knots, that most sailors will never experience. A Legacy of Support Portland Ship Yard has been a proud sponsor of the BVI Spring Regatta for the past four years, a tradition we are committed to continuing. Our involvement underscores our dedication to the sailing community and our belief in fostering competitive excellence. PYS owners Phin & Joanna Sprague have been supporting sailing events since Antigua Classic’s Week many years ago. This support continues now with events like the BVI Spring Regatta and others all year long. Meet the Sailors Brent Sullivan Brent has been an integral part of the local sailing scene for many years. His passion for the sport is evident in his commitment to continuous learning and participation in various regattas. Brent's experience and leadership were invaluable assets to the Timbalero 3 team. Brent carries years of professional sailing experience mostly on mono hulls with him to Timbalero 3 and was excited to learn the ins & outs of trimming sails while foiling. Rob Windsor Rob Windsor is a renowned marine professional with a rich history in offshore racing. His expertise spans numerous high-profile sailing events. Rob's collaboration with Brent on Timbalero 3 brought together a formidable combination of skill and experience, that has seen the podium in multiple events prior to this memorable week. The Vessel: Timbalero 3 Timbalero 3 is a Gunboat G4, foiling catamaran known for its speed and agility. Designed for performance, the G4 series represents, what was at the time, the pinnacle of modern multihull racing technology. Timbalero 3's participation in the regatta marked a significant milestone, showcasing the capabilities of foiling catamarans in competitive settings. Her future looking design and concepts made for great video at the event. Special thanks to Owner Evadro Perez and Mariano Ruiz (Captain). The Regatta Experience The 2025 BVI Spring Regatta presented a mix of challenging conditions and exhilarating racing. Competitors faced varying wind patterns and tactical courses that tested their skills and adaptability. Despite this being their first time on the boat the crew had the boat flying at times While Timbalero 3 did not achieve a podium finish, the experience gained, and the lessons learned are invaluable for future competitions. A little more time on the boat and who knows? Looking Ahead Portland Ship Yard remains steadfast in its support of sailors like Brent Sullivan and Rob Windsor. We recognize that success in sailing is not solely measured by victories but also by the growth, resilience, and passion exhibited by those who take to the seas. As we look forward to future regattas, we are excited to continue our sponsorship of events like the BVI Spring Regatta. These platforms not only highlight the talents of individual sailors but also strengthen the global sailing community. Explore More To learn more about the BVI Spring Regatta and view highlights from the 2025 event, visit the official website: BVI Spring Regatta Join the Conversation Portland Ship Yard is proud to be part of a community that celebrates the spirit of sailing. We commend Brent Sullivan and Rob Windsor for their dedication and look forward to supporting their future endeavors on the water. Stay connected with us and share your sailing experiences using the following hashtags: #PortlandShipYard #BVISpringRegatta2025 #Timberlero3 #GunboatG4 #SailingLife #MultihullRacing #SailingCommunity #MaritimeExcellence #FoilingCatamaran #SailPortland
Portland, ME – 3/14/2025 – Portland Yacht Services (PYS), a premier full-service boatyard, is proud to announce its acquisition of the Portland Boat Show, a long-standing staple in the New England maritime community. This strategic acquisition ensures the continued success and growth of the region’s most anticipated boating event while reinforcing PYS’s dedication to the industry. The Portland Boat Show has been a cornerstone event for boaters, marine industry professionals, and enthusiasts alike, showcasing the latest vessels, marine equipment, and services. Under new ownership, the show will maintain its commitment to delivering an unparalleled experience for exhibitors and attendees while exploring new opportunities for growth and innovation. “We are thrilled to bring the Portland Boat Show into the Portland Yacht Services family,” said Jason Curtis, VPO of Portland Yacht Services. “This acquisition aligns with our mission to support and enhance the boating community in New England. Our team is eager to build upon the show’s rich tradition and introduce new elements that reflect the evolving needs of boaters.” The PYS team has over thirty years of experience running the Maine Boat Builders show and this experience will carry over in order to help provide a seamless transition. PYS plans to expand exhibitor offerings, enhance educational programs, and introduce interactive experiences that highlight advancements in marine technology, sustainability, and boating safety. The next Portland Boat Show is scheduled for February 25th to March 1st, 2026, at The Portland Sports Complex 512 Warren Ave Portland Maine, promising an even greater experience for the industry and boating enthusiasts alike. For more information about Portland Yacht Services and the Portland Boat Show, visit https://www.theportlandboatshow.com/or contact Jason Curtis at 207 774-1067. Portland Yacht Services is a full-service boatyard located in Portland, Maine, offering premier marine repair, maintenance, and storage services. With a strong commitment to supporting the boating community, PYS provides top-tier services and hosts events that promote maritime excellence.
Maine’s maritime heritage thrives through the collaborative efforts of Portland Yacht Services (PYS), Portland Ship Yard, and The Landing School. PYS, founded in 1981, provides world-class boat maintenance and repair, while the adjacent Portland Ship Yard specializes in refits and servicing commercial and government vessels. The Landing School in Arundel trains future marine professionals, offering programs in boatbuilding, marine systems, and yacht design with a high job placement rate. Their partnership ensures a seamless transition from education to industry, integrating hands-on training with real-world applications. Through continuous innovation, state-of-the-art facilities, and industry-responsive education, these institutions play a vital role in preserving and advancing Maine’s boatbuilding legacy
Portland Yacht Services & SailMaine: A Shared Commitment to the Waterfront Community
Portland Yacht Services & SailMaine: A Shared Commitment to the Waterfront Community
