ALL AT SEA QUIZ

Rarely has the task of restoring a classic power boat caused such a buzz among marine experts as when Stuart Sawyer’s Fairey

Swordsman 40 Freebird was placed in the hands of Mylor Yacht Harbour’s marine engineers, shipwrights, technicians and associated craftsmen.

From Stuart Sawyer’s own boyhood dreams of being James Bond, to lead marine electrician Mark Howard’s memory of racing his radio-controlled model Swordsman as a child, to Mylor

Yacht Harbour owners Roger and Dinah

Graffy’s lifelong passion for the beauty and heritage of these Fairey classics – the mission involved transforming a 1960s marine icon from neglected and broken to prime condition.

The project was far from straightforward beginning with fi nding and purchasing the right boat - with the understanding that both original

Caterpillar C7 engines had serious issues through years of disuse and, of course, dealing with Covid. Classic calling As an ‘in the blood’ waterman, Stuart’s previous power of choice has been the wind, which propelled him through a world-class sailing and windsurfi ng career. But when it came to seeking out a boat for his whole family Freebird, with its classic lines, appealed to everyone – despite her mouldy decks, oil fi lled bilges and rotting mast.

“I love that Fairey represents the best of British classic design, for both sailing and motor craft,” said Stuart. “Their commitment to performance and seakeeping remains timeless even today, with Sir Richard Fairey founding the fi rm around his passion for aviation and boats in the 1940s and his son producing the fi rst motor cruisers in the 1960s as a fan of offshore racing. I knew through friends and colleagues that Mylor Yacht Harbour’s Marine Team do a fantastic job.”

Mylor’s owner, Roger Graffy, confi rmed it was exactly the kind of project they like to be involved in: “As a child of the ‘60s I have always loved these boats and it was a daunting, but also welcome, challenge

Freebird berthed at Mylor Yacht Harbour. All images: Mylor Yacht Harbour to have one coming for such major works. Freebird is an exceptional boat and I know I speak for everyone here in expressing our pride in our involvement in this special project.”

In need of care A survey confi rmed the vessel was suffering from lack of use, care and maintenance, but sea trials in the Carrick Roads off Falmouth exposed major issues with the engines and the dawning realisation that they would need to be replaced.

Over a period of four months Mylor’s engineering manager, Nathan Percival, worked closely alongside Stuart, while lead engineer Chris Powell headed up all the engineering works, which included sourcing the new Caterpillar C7.1 engines and the diffi cult task of fi tting them into the vessel. Due to the classic design of the Fairey Swordsman 40, modifi cations had to be made to the engine beds and mounts to ensure they fi tted like a glove and, having been sat dormant for a while, the fuel systems were fully cleaned to ensure optimum performance, which is always good practice for any vessel. Then, to complete the installation, new exhausts were fi tted.

“The biggest challenge was fi tting a modern version of the original Caterpillar engines into a slim classic design,” said Chris Powell. “To keep the heritage and the distinctive Swordsman ‘sound’ we supplied two new 455hp Caterpillar C7.1 engines, but they are slightly deeper than the originals, so we had to redesign, modify and rebuild the engine bearers and mount points to accommodate them.”

Authenticity is key Attention to detail and authenticity was key for Stuart. With the main dashboard and cockpit control panels rusted and missing buttons, Mylor found the original supplier and arranged for new panels to be cut and powder coated to maintain the original look and feel.

As Stuart insisted on having the look and feel of the original analogue gauges, it meant integrating the new engines’ LCD control panels and a modern

New engine installation for Freebird

chartplotter around them. The Marine Team installed a Raymarine Axiom 9 control system and AIS 700 chartplotter. To ensure the Axiom’s look was in keeping with the Swordsman’s classic style, Mylor Yacht Harbour’s lead electrician Mark Howard sourced the original style white and chrome analogue dials to replace the digital controls of the new Cat engines.

The work held a special place in the heart of Mark who said, “I have still got the radio-controlled model of a Swordsman I raced as a kid and it is great to be working on Freebird, making sure her looks are just as good as her performance - I have loved it.”

While the Mylor Marine Team focused on the engines and electrics, Stuart asked local marine tradesmen Tim Seaman, from Formation Marine, and carpenter Rob Holdroff to work on the exterior repairs and interior fi t-out respectively, completely restoring the external lockers, teak decks, topsides, structure and mast and fi tting out all interior lockers, berths, galley, hull fi ttings and heads. Back on the water Of the extensive work carried out, Stuart said, “The restoration of Freebird was great to watch unfold: it was a real bonus having such a connected Cornish team who genuinely wanted to work on her, all interested in every aspect of the refurbishment and delivering real craftsmanship and high quality as the classic boat started to shine though again.”

Freebird was re-launched last year with the Graffys joining the owner to put her through her paces (she opens up to an adrenalin-fi lled 34 knots) – and Roger declaring her handling an “absolute dream”.

She lived up to the Sawyer family’s hopes in every way as they tested out her peak performance and luxurious creature comforts during autumn trips and overnights around the Carrick Roads and the secluded Helford River.

Every vessel has a story to tell and, classic or modern, a range of on-going needs… It is heartening that the future for this classic is looking rosey. www.mylor.com

Freebird berthed at Mylor Yacht Harbour