A tired but structurally sound Legend 2500 named Pasha has come out the other side of a full refit looking, in the words of the service technician who led the work, "brand new."
Blake Jackson, a service technician at Rayglass, was part of the team that repowered, reupholstered, and refitted the well-used 2500 over several weeks. The boat had high hours and plenty of wear, and had probably caught a few hundred snapper along the way.
The centrepiece of the project was pulling out an old 350 petrol V8 and replacing it with a Mercury Victory 270hp diesel. The catch: the old engine was far bigger than the new one, meaning the engine bay needed significant modification before anything could go in.
"We had to cut stringers on an angle for clearance, move the pedestals where the engine mount sat," Blake explains. "The engine hatch sizes were increased … we also cut out and enlarged the area of the hatchhole, then also cut a new front engine hatch that is deeper to cater for the larger motor."
Before the new powerplant could be lifted in, the team also had to install new battery cables, switches, soundproof lining, fuel lines, and mounted fuel filters. Frontloading that preparation paid off when installation day arrived.
"When the motor finally went in it was mostly ready," Blake says. "You can estimate and measure but you only know exactly how things will fit when the motor goes in, so there was a bit of in and out, a few minor adjustments."
The repower was far from the whole story. Service Advisor Mike Thompson had completed a similar install on his own boat and contributed his knowledge of the process. Team members Tim, Natie, and Andre then got stuck into a cut and polish and a full interior refurbishment. New u-Dek, fresh graphics, and FloCoat applied throughout the bilge rounded out a top-to-bottom job.
For Blake, the owner's reaction made the hours worthwhile. "He was so rapt. He talks to Tony every now and then and has been saying how great the boat is. How much better the fuel economy is with the new engine. We spent all this time getting Pasha perfect, so hearing that feedback goes a long way."
The satisfaction extends beyond the yard. "I spend a lot of time out on the water myself and Rayglass is a staple brand in every marina. When I go out to Waiheke I see multiple boats I worked on just like Pasha and I say, I know that person, I worked on that boat. It's really rewarding to see them all out there enjoying it."
