Sir Robin and Suhaili, in his own words

PICTURES OF YESTERYEAR - MANAGED BY PPL PHOTO AGENCY - COPYRIGHT RESERVED PHOTO CREDIT: Bill Rowntree/PPL TEL: +44 (0) 1243 555561 E-mail: ppl@mistral.co.uk Web: www.pplmedia.com *** Circa 22nd April 1969: Robin Knox-Johnston aboard his 32ft yacht SUHAILI off Falmouth, England after becoming the first man to sail solo non-stop around the globe. Knox-Johnston was the sole finisher in the Sunday Times Golden Globe solo round the world race, having set out from Falmouth, England on 14th June 1968 aboard his tiny 32ft ketch Suhaili. It was a time when the Flat Earth Society was still in existence, and even seasoned yachtsman thought it to be an impossible feat. For everyone else it was; Robin was the sole finisher among 9 starters to complete this 30,000 mile supreme endurance race, organised by the Sunday Times newspaper.

Sir Robin and friends set about bringing Suhaili to sailing condition three years ago. This is their story

Chris Gillingham/PPL. Suhaili at the Hamble Classics Regatta, September 2016

After one solo circumnavigation, two transatlantic crossings, a voyage to Iceland and five years drying out in the clinically clean air of the National Maritime Museum in Greenwich, Sir Robin Knox-Johnston’s Suhaili was in need of restoration. The task of bringing her back to cruising rather than concours condition has taken three years and countless hours, by a core team of four plus friends working weekends who have been just as keen as Sir Robin to see the yacht back in good fettle again.

Suhaili’s restoration took longer than it did to build her in the first place. The biggest problem the team had was to replace all the iron fastenings holding the 1¼ inch teak planking. The fastenings were exhibiting the equivalent of ‘nail rot’ in a roof, and the tell-tale signs of weeping rust stains were clear to see inside and out. This meant stripping out the entire interior, including bulkheads, before removing 1,400 fastenings and replacing them with bronze ones – at £5 a time! It was not just the cost that caused Sir Robin to exclaim. The old iron ones proved devils to get out. “To start with, we were using a hammer and punch and found we could only remove and replace 8-10 a day,” he recalled.

“The problem lay in the way Suhaili was built,” said Sir Robin. “The Indian boat builders were still using medieval bow drills back in the 1960s, which compared to modern electric drills did not cut an accurate hole.”

The iron fastenings, hammered through the planking and ribs, tended to follow the wavy line of these holes, and 50 years later when much of their iron had wasted away, the metal would take any blows from the punch. First, they tried the latest hammer drills, but they too failed to pack the punch required, and the problem was only solved when Ian Sinclair, one of the brigade of Suhaili’s friends, brought in a compressor and used a couple of pneumatic hammer drills to attack each bolt from either side.

Credit: Barry Pickthall/PPL. Work in progress

“Working simultaneously from inside and outside the hull, we got each one to start moving by hitting the fastenings first from one way and then the other. That did the trick, and productivity increased from eight a day to 80 a day, but the work still took two men the best part of 18 days spread over several months – and the noise is still ringing in our ears!”

Keel bolts

If the fastenings had corroded, what about the keel bolts? They proved just as much a challenge to remove. There are 14 of them and they simply wouldn’t budge, however much hammering and leverage was applied. The answer came from an 80-year-old Bursledon shipwright who told Sir Robin of an old trick. “Drill a small hole down beside each bolt and keep pouring Sarson’s vinegar down. It must be Sarson’s – no other vinegar works,” he told them. Sir Robin and shipwright Keith Savill, who served his time at Tough Brothers at Teddington back in the 1960s, were sceptical, but they gave it a try anyway. “It worked incredibly well. How, I don’t know,” said Sir Robin. “We kept topping up the holes with vinegar for a day and left it to soak in overnight – and bingo. The next morning the bolts began to move easily. We hit them once with a club hammer, which released them from the wood and then they turned relatively easily.”

Remarkably, the first bolts to be removed showed so little corrosion that he decided to replace only one in four of them.

Suhaili’s keel was laid down in the Colaba Workshops, Bombay, back in 1963. They knew a thing or two about casting iron in those days, for although they didn’t have the expertise to cast it in one length (the keel is in two sections dogged together in the middle) the foundry men knew all about adding oil during the cooling process, which penetrates the metal to inhibit rusting later in life. Indeed, Suhaili’s 2¼ ton keel shows very little pitting after 53 years.

Robin and his team also took the precaution of replacing Suhaili’s original iron floors, and in doing so, lowered the companionway by two inches to increase the headroom in the cabin.

Indian teak

Back in the 1960s, Indian teak was in plentiful supply, and used for her entire construction; keelson, planking, frames, deck and cabin top. Her 1¼in thick planking weighs 6 tons alone, so it is not surprising perhaps that Suhaili floated 2in below her marks when first launched in 1965. But it is wonderful wood to work with, and after stripping the entire hull, the sanding down to prepare for new paint brought the teak back to a silk-smooth finish and a lovely oily feel to the hand.

Sir Robin recalled: “The Indian craftsmen used 19th Century hand-tools to shape the wood, and we would watch, fascinated, as the adze, handled so casually, produced as fine a scarph as any modern plane.”

What interested Keith Savill most was how the Indians sealed the plank seams. “They used a wooden plane to cut a central rebate along the top and bottom edges of each plank, then poured some medieval black gooey mix along the top joint to act as a caulking, which has kept the water out for 50 years. That’s longer than any modern caulking compound is likely to last.”

The keel to keelson joint, together with the forefoot, which had caused some leaking in the past, was sheathed in glassfibre, and then faired with epoxy filler prior to the undersides being given three coats of Coppercoat epoxy antifouling. “We tried Coppercoat on our Clipper Race training yachts last year and found it very effective, so why not try it on Suhaili too?” said Sir Robin of his company Clipper Venture’s fleet of round-the-world race yachts. The coating has been so successful that it’s now used on the whole of the Clipper Race fleet.

Sir Robin used Hempel Primer Undercoat and Brilliant White gloss for the topsides again, after a French yachtsman mistook Suhaili for a plastic replica when she was last painted. “He insisted that she was glassfibre and remained convinced until I took him below decks to see the planking and ribs. I took his confusion as something of a compliment to the finish we achieved,” Sir Robin said with a laugh. Seeing her now back in the water with freshly painted livery, the same smooth, high gloss finish is likely to fool others into thinking the same.

There is not too much varnish work on Suhaili. The natural look is restricted to her original hatches on foredeck and main companionway, kingpost and raised toe rail amidships, which was replaced during the restoration to solve a deck leak issue. These were given several coats of Le Tonkinois Vernis No 1, a natural oil varnish used on the Cutty Sark. “I discovered it during my time as a Trustee of the ship. It is both hard-wearing and long-lasting, and because of the natural oil, it has particularly good adhesion to teak,” he said.

Varnishing the toe rail and companionway hatch, this product was certainly easy to apply and we got a good finish because the varnish’s extended drying time kept a wet edge, so that brush strokes blended in seamlessly. The minimum overcoat period is 24 hours, and longer in colder conditions. Despite this drying time, which takes the rush out of applying it well, this varnish does turn to jelly quite quickly, so we always decanted just the amount we needed into a plastic container, and kept the lid on the tin firmly sealed.

Sir Robin has another tried-and-tested trick, this time for cleaning teak decking. “I don’t like scrubbing or abrading the deck in any way because, over the years, this simply wears the wood away,” he said. Instead, he uses salt water and a soft brush to keep the green mould at bay, and a diluted oxalic acid wash to bring the teak back to its original colour. This was one of the last jobs to be done after Suhaili was re-launched last September, and looking at three years of mould and dirt that had become impregnated into the wood, there were several sceptics among us. But yes, the salt water did kill the green, and the oxalic acid, applied with a paintbrush, did restore the teak planking to a sun-bleached light brown.

Suhaili is on her third set of masts. Her first mainmast broke in Durban during the yacht’s delivery from India to the UK in 1966 and was replaced with a hollow spar. The heavy mizzen mast was replaced before setting out on the Sunday Times Golden Globe Race in 1968 with another hollow section, and the original still stands as the flagpole at Benfleet YC. Suhaili was later rolled and dismasted in 1989 when caught in a storm mid-way across the Atlantic, while Sir Robin was returning from his ‘Columbus voyage’ to prove the accuracy of a mariner’s astrolabe. She was re-rigged with a set of Sparlight alloy masts which remain in good order.

Photographic reference

Credit: Bill Rowntree/PPL. Circa 1969: Suhaili moored up against the harbour wall at the Falmouth Boat Company yard at Flushing, after winning the Sunday Times Golden Globe Race in 1969.

Below decks, at the time of writing, is still ‘work in progress’. The original interior was cut out carefully and put in store to act as templates for the new fit-out, but for some reason that still baffles Sir Robin and Keith Savill, nothing seemed to fit back as it should. Luckily we have all of Sunday Mirror photographer Bill Rowntree’s archive, taken before and immediately after the Sunday Times Golden Globe Race, to provide pictorial reference, and with a mix of these and Sir Robin’s recollections of what went where, Keith has rebuilt Suhaili’s interior, largely as it was.

First he had to put in a new floor and sole bearers, before he and Sir Robin sketched out the interior plan in pencil on the white primered cabin sides. The problem was that not everyone realised the importance of this graffiti art, and it was difficult to stop grandson Ralph Knox-Johnston and apprentice Andrew Shrimpton from keenly covering them with another coat of primer!

Two additions to Suhaili’s original plan has been the inclusion of two fixed berths in the forepeak where sails were once stored, and a door to the heads to give female occupants a degree of privacy. For the moment, a toolbox jammed against the door has to suffice as a lock, but the fixed berths, with stowage beneath, now replace two folding pipe-cots that Sir Robin never liked.

Her engine, a Perkins Prima M50 50hp diesel, started on the button despite the dirt, dust and rust deposits that have built up in the engine enclosure beneath the companionway. This is Suhaili’s third engine and was fitted in 1988. Once the initial plume of back smoke had dissipated, the engine ran smoothly enough and is likely to last a few more years. Here previous motors were BMC Captains – marinised versions of the 4-cylinder diesels used to power London taxis. The first gave up the ghost during the Sunday Times Golden Globe Race, and the second, paid for by The Sunday Mirror in an effort to hurry Sir Robin to London to meet his sponsorship commitments after the race, lasted 19 years. Sir Robin is hoping the current Perkins will still be purring three decades on, when he and Suhaili will be guests of honour at the start of the 2018 Golden Globe Race in Falmouth, marking the 50th anniversary of his departure in the Sunday Times race.

Paintwork

The deckhead has been painted with white Dulux Bathroom water-based matt paint, which has a mould inhibitor within the mix, while the rest of the insides have now been given a gloss finish using the same Hempel Brilliant White as on the topsides. A compact charcoal burning stove now resides in the main cabin to keep the boat warm and dry during the winter.

There is still the matter of re-wiring the boat and replacing the tiller, the third one in her life, which is gently rotting away from the tip back.

Certainly she is a good, solid boat with a pedigree and history that is worth preserving, though not everyone thought so during her restoration. During Suhaili’s long stay on hard standing at the top of Portsmouth Harbour, one sceptic, looking at her anonymous stripped-down hull, called out to the team: “She’s hardly worth saving!”

Sir Robin, equally anonymous is his paint-splattered boiler suit, called back: “Well, we think she is.”

“Nah, you are wasting your money,” came the derisory reply.

“Well, one thing’s for certain: you couldn’t afford her!” retorted Robin, which drew a quizzical look from his dissenter, who walked off totally unaware of who or what he was talking to or about. “And I wasn’t about to put him straight – I left him to look us up online,” Robin laughs. The good news is that the National Historic Ships Register has finally agreed to include Suhaili on its list of vessels worthy of being saved for posterity. For years, the lower limit had been set at 33ft. Suhaili’s hull length (without spars) fell 7in short, but following a campaign to have this famous yacht included, Martyn Heighton, Director of the Register, wrote shortly before his untimely death in November that with Sir Robin’s blessing, Suhaili will now be included in the Historic National Fleet.

In Sir Robin’s own words…

Credit: Barry Pickthall/PPL. Sir Robin Knox-Johnston at the helm after the three-year restoration

“Yes, there is still work to be done, but I am very fond of her. She has been part of my life since I was 23. I couldn’t imagine life without her, and getting her back sailing is when she is looked after best. She doesn’t like going to windward, but then neither do I. She’s an old design; not a fast boat, but she is very seaworthy.

We developed Suhaili’s Bermudian ketch rig ourselves, after the original ERIC plans supplied by a company in Poole failed to include a detailed rigging plan. The rig plan turned out to be an ‘extra’ and with time short – we wanted to launch her before the North-East Monsoon set in – we decided it was easier to start from scratch, after consulting Douglas Phillip-Birt’s handbook The Rigs and Rigging of Yachts and Eric Hiscock’s Cruising under Sail.  I’m pleased we did because Suhaili is so well-balanced that she is able to keep to a course. If she had not been, I might not have finished the Golden Globe Race, because after my Admiral self-steering broke 1,500 miles west of Cape Horn, I relied on her ‘balance’ to get me home.

Our first event since re-launching in late 2016 was the first Hamble Classics regatta organised by The Royal Southern Yacht Club, when there was more windward work than I and Suhaili would have liked. I’m now looking forward to going cruising in her again with family and friends. We’ve just enjoyed a weekend sail to Cowes with six other yachts owned by Clipper Ventures employees. The offwind sail back to Portsmouth was enjoyable.

I’m also looking forward to 2018 and the events planned to mark the 50th anniversary of the original Sunday Times Golden Globe Race. The French National Maritime Museum is allowing Bernard Moitessier’s yacht Joshua to sail over from La Rochelle and we are likely to be joined by Francis Chichester’s Gipsy Moth IV and Alec Rose’s Lively Lady when Suhaili acts as start vessel for the 2018 Golden Globe Race.”