05/18/2026
Just to give you an idea of the size of this project…
* This is just restoring the hull only. This does not include any of the deck or walkway construction.
Hull Project
A project of this scale—permanently mooring an 80-foot steel vessel after sheathing the entire 2,400 sq. ft. hull with two structural layers of 1708 cloth—demands an uncompromising commercial-grade spec.
Because the vessel is kept in the water, it requires an impermeable chemical barrier, flawless structural lamination, cosmetic fairing to hide heavy overlapping seams, and high-performance bottom and topside coatings.
Project Sizing & Material Requirements
Total Hull Surface Area: 2,400 sq. ft.
Target Breakdown: 1,400 sq. ft. Below Waterline (Bottom) | 1,000 sq. ft. Above Waterline (Topsides).
1708 Fabric Matrix (2 Layers): Total fabric area becomes 4,800 sq. ft. Adding a 15% safety margin for the mandatory staggered 3-inch overlaps results in 5,520 sq. ft. of fabric.
TotalBoat 5:1 Epoxy Matrix: Two layers of heavy 1708 cloth require 150 gallons of mixed epoxy for wet-out (1 gal per 32 sq. ft. per layer). Adding 15 gallons for the initial substrate seal and final fabric weave-filling coats brings the requirement to 165 gallons of mixed epoxy.
Comprehensive Master Budget
This tier of purchasing qualifies for commercial/bulk volume discounts. Prices below reflect standard retail markers; calling commercial marine distributors should yield an estimated 15% to 20% discount on bulk lines.
Item Category Material / Product Breakdown Est.
Unit Price Quantity Estimated Cost
1. Anti-Corrosive Primer International Paint Bar-Rust 235 (2 base coats on bare steel) $375.00 / 5-Gal Kit 8 Kits (40 Gal) $3,000.00
2. Structural Resin TotalBoat 5:1 Marine Epoxy Resin Kit (with Slow Hardener) $570.00 / 4.5-Gal Kit 37 Kits (166.5 Gal) $21,090.00
3. Structural Glass 1708 Biaxial Cloth (50-inch wide bulk commercial master rolls) $270.00 / 50-yd Roll 13 Rolls (5,850 sq ft) $3,510.00
4. Fairing Compound TotalBoat TotalFair Epoxy Fairing Compound (To smooth seams and hull sides) $165.00 / 2-Gal Kit 4 Kits (8 Gal) $660.00
5. Below-Water Finishes TotalBoat Krypton Copper-Free Bottom Paint (Multi-season dual-biocide anti-fouling) $290.00 / Gallon 10 Gallons (2 coats) $2,900.00
6. Above-Water Finishes TotalBoat TotalProtect Epoxy Barrier Primer (3 coats over fairing compound) $145.00 / Gallon 8 Gallons $1,160.00
TotalBoat Wet Edge Polyurethane Topside Paint (2 finishing color coats) $95.00 / Gallon 6 Gallons $570.00
7. Consumables & Prep Sandblasting media, 80-grit grinding discs, acetone, bulk safety gear Varies Lump Sum $1,000.00
TotalBoat 5:1 Pumps, 10" solvent rollers, finned aluminum rollers, squeegees Varies Bulk Pack $1,500.00
Project Grand Total Raw Materials Baseline (Self-Executed Labor) $35,390.00
Project Ex*****on Schedule (24-Day Timeline)
This continuous timeline requires a disciplined 4-person crew working in a climate-controlled build shed or stable outdoor environment (~75°F / 24°C).
The hull is tackled in 4 distinct 600 sq. ft. quadrants(Port/Starboard Bow, Port/Starboard Stern) to remain inside the chemical overcoat windows.
Phase 1: Substrate Preparation (Days 1–4)
Days 1–2: Blast or mechanically scale the 2,400 sq. ft. hull to a near-white metal standard with a 2-to-2.5 mil angular anchor tooth profile.
Day 3: Pressure wash with fresh water to strip invisible salt crystallization. Allow to air dry completely.
Day 4: Execute a full chemical wash of bare steel using clean rags heavily soaked in pure acetone.
Phase 2: Bar-Rust & Layer 1 Application (Days 5–8)
Day 5 (Zone 1):
07:00 AM: Apply the first coat of Bar-Rust 235.
09:00 AM: Apply the second coat of Bar-Rust 235.
11:30 AM: Once the Bar-Rust reaches a tacky state, roll out a thin bed coat of unthickened TotalBoat 5:1 Epoxy.
12:30 PM–06:00 PM: Lay down the first structural layer of 1708 fabric. Fully wet it out using 1-quart mixed batches of epoxy, forcing out air using aluminum finned bubble rollers.
Days 6–8: Repeat this precise routine for Zones 2, 3, and 4. Ensure all perimeter edges of the 1708 fabric overlap onto the neighboring zone by exactly 3 inches.
Phase 3: Layer 2 Application (Days 9–12)
Day 9 (Zone 1 - Layer 2): Scuff the previous layer if it has cured past 24 hours. Lay down the second layer of 1708 fabric directly over the first. Critical: Offset the seams of this second layer by at least 12 inches away from the first layer's seams to prevent thick structural ridges.
Days 10–12: Complete Layer 2 across Zones 2, 3, and 4.
Phase 4: Weave Filling & Fairing (Days 13–16)
Day 13 (Fill Coating): Roll two consecutive "hot coats" of unthickened TotalBoat epoxy over the entire hull to fill the coarse structural pattern of the 1708 weave.
Day 14 (Cure Window): Allow the entire epoxy mass to chemically lock and cure hard for 24 hours.
Day 15 (Blush Wash & Sanding): Scrub the entire hull with warm water and abrasive pads to strip away transparent amine blush. Sand the entire 2,400 sq. ft. surface with heavy 80-grit sanding blocks.
Day 16 (Fairing): Apply TotalBoat TotalFair compound using wide drywall trowels over all fabric steps, overlaps, and minor hull depressions.
Phase 5: Topside Paint & Bottom Painting (Days 17–21)
Day 17 (Fairing Sanding): Sand the cured fairing compound smooth using 120-grit media.
Day 18 (Topsides Priming): Apply 3 protective coats of TotalBoat TotalProtect Epoxy Barrier Primer to the above-waterline sections.
Day 19 (Topsides Finish): Apply 2 high-gloss color coats of UV-resistant TotalBoat Wet Edge Polyurethane Paint to the topsides.
Day 20 (Bottom Painting - Coat 1): Roll the first coat of Krypton Anti-Fouling Bottom Paint below the waterline.
Day 21 (Bottom Painting - Coat 2): Roll the second coat of Krypton Anti-Fouling Paint.
Phase 6: Final Structural Cure (Days 22–24)
Days 22–24: Leave the vessel completely undisturbed for a minimum of 72 hours. This allows the anti-fouling solids to flash off and ensures the massive structural epoxy core achieves peak cross-linked density before crane straps lift the hull into the water.
The total approximate cost for this project, exactly as outlined in the 24-day schedule, is $35,390.00.
This assumes you are purchasing materials at standard retail rates and performing the labor with your own crew.
Quick Cost Sanity Check
Materials & Coatings: $32,890.00 (Covers the Bar-Rust 235, 37 kits of TotalBoat epoxy, 13 rolls of 1708 cloth, fairing compounds, barrier coats, topside paint, and anti-fouling bottom paint).
Tools & Equipment: $2,500.00 (Covers sandblasting/grinding media, 5:1 pumps, rollers, squeegees, safety gear, and mixing supplies).
To finance this project, we will be creating (20) “Pirate Lord” Founder Memberships. ($2000) donation to our 501(c)3 nonprofit.
These Memberships will establish you as a Founder of the “Host of Sparrows”. You will be invited to “Members Only” cruises/events, zero cost passage upon any cruise open to general public for you and Spouse/guest, 20% off Member pricing for food/beverage/merch purchases; for life. (First come - First served basis, based upon ship’s passenger capacity).
Corp/Business Membership - ($4000) allows any (2) employees/clients/guests to use membership.
We are not skimping on this ship. It will be amazingly fun cruises of many different types. Our main mission is to provide “Neverland” specialty cruises for terminally ill children and families, but there will be many different types of cruises for everyone.
Restoring the “Whippoorwill” preserves Kansas History. The story of the Whippoorwill will be preserved and honored! Help us to turn tragedy into a wonderful resource for creating lifelong amazing memories!
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We also humbly request you consider contributing via a “Membership” (DM for details) or even just “Donating” a few dollars thru the fundraising link below. It is tax deductible!
