Navaia Newsletter — The Rebirth of Bossy Boots
Back in the summer, I bought Bossy Boots — a solid, honest little Contessa 32 with a dry hull and good bones. She was never going to be flashy, but I saw something in her: potential. A boat with real character, capable of becoming a small but mighty part of the Navaia fleet.
What I didn’t fully appreciate at the time was just how deep the refit would go.
What follows is the story of her transformation so far — a journey of stubborn bolts, hidden corrosion, diesel bugs, and the kind of unexpected discoveries that turn “a quick winter tidy-up” into a full-blown resurrection.
Step One: The Uh-Oh Moment
After a few early outings, we discovered the engine shaft seal needed replacing. Not unusual. But to get to it, Bossy Boots needed to come out of the water. Once she was lifted, the first domino fell…
The shaft runs through a stuffing box — old-school, reliable technology using grease and impregnated rope to keep the sea where it belongs. But to refurb it, the prop shaft had to come off the engine. To get the shaft out, the rudder needed to come off.
Daunting, yes. But the Contessa Owners’ site had a good guide, so we followed it. A few hours later the rudder dropped — and that’s when we found the real problem.
The rudder stock was badly corroded. Very badly.
We tried to repair it, but after a full day of dismantling and assessing, it became clear: the rudder was over 50 years old, waterlogged, and no longer safe. For personal cruising it might have survived. But for commercial use? Offshore training? Racing? No chance.
So we ordered a brand-new rudder from Jeremy Rogers — a big investment but a huge upgrade. The old rudder was full of water and completely unbalanced. This one will last decades.
The Stern Tube Surprise (and the Hidden Nightmare Behind It)
Back to the stuffing box…Except not quite.
With the shaft removed, we saw the leak wasn’t just the stuffing box. The brass stern tube running through the skeg had come loose from its bonding to the hull — another common Contessa problem — and it had been leaking for long enough that the hidden void around it, originally filled with foam, was now holding water.
This void is almost impossible to access. It sits behind the engine, deep inside the skeg, in a place no sane boatbuilder expects anyone to reach again.
My first thought was: Oh no… we’re going to have to move the engine.
But with enough contortion — lying half-twisted on the quarter berth — I realised I could just reach it with one hand. Not comfortable, but possible. So I cut into the void and began pulling out the soaked foam by hand. It took days, countless broken gloves, and a lot of swearing, but eventually the space was empty and dry.
Only then could we refill it properly with epoxy foam, seal it again, and move on to installing the new GRP stern tube — a modern, no-corrosion, long-term fix.
To get the alignment perfect, my machinist friend Robin — an ex-Contessa owner — built a custom rig to bore out the old opening precisely in line with the engine. In no time, we had a clean, straight hole ready for the new tube, which we bonded in place after a crash-course in fibreglass and epoxy. Another massive job done.
The Rebuild Begins
With the stern tube replaced, we rebuilt the drivetrain. A new engine coupling went on, and rather than upgrading to a modern dripless seal, I chose to keep the traditional stuffing box. It’s simple, it’s bulletproof, and I like dependable old technology. It just needs regular grease and adjustment — a fair trade for reliability.
While she was out, we also tidied the hull and gave her a fresh coat of red antifoul. She looked fantastic. In late September, she went back into the water.
New Electrics, New Life
Next came the electrics: AIS, a proper battery charger, a full bilge pump system, and a complete tidy-up of everything behind the panels.
Thanks to the experience of rebuilding the electrical system on my HR43, this time I had the right tools, the right patience, and the right methodical approach. Slowly, wire by wire, tidying, labelling, securing…Electrics are simple when you take your time.
Days (and probably weeks) later, everything worked beautifully. Safe, clean, reliable — and ready for commercial use.
The Engine: Good News… and Then Diesel Bug
I brought in a specialist to double-check the engine. Despite her age — late 80s or early 90s — she ran beautifully. Rebuilt in the early 2010s, and it shows. Smooth, steady, surprisingly healthy.
Then we checked the fuel filter. And found diesel bug.
Every boat owner’s nightmare.
So out came the stainless-steel tank. Inside was the usual black sludge that can starve an engine at the worst possible moment.
Back to Robin it went. He opened it, steam-cleaned it, and we removed the old sight gauge (a known weak point) and replaced it with a safer electronic one. We also added an inspection hatch for future access. Reinstalled with new hoses, the tank now looks better than new.
Standing Rigging… and Yet Another Twist
The final big job was new standing rigging. I took Bossy Boots to Ocean Rigging in Lymington — they know Contessas inside out.
As they tried to unstep the mast, something felt wrong. It wasn’t moving. At all.
When it finally came free, the reason was obvious: heavy corrosion at the mast foot. It had been repaired years ago but had deteriorated badly.
Could it have survived gentle cruising? Probably. Could it survive commercial work and offshore races? Absolutely not.
A new mast was the only responsible choice.
And in one of those lucky moments you don’t question, Jeremy Rogers — just around the corner — had a brand-new Selden mast and boom in stock and even on sale. Decision made.
She was lifted again and taken into the Jeremy Rogers factory, where she is now having the deck adjusted and the mast prepared. This time all lines will run aft to the cockpit — perfect for training and shorthanded sailing.
And Still More Surprises…
Since she was out again, I decided to replace some raw water hoses and their associated skin fittings. One of the old ones sheared off in my hand.
If that had happened at sea…
A new Blakes fitting is now going in. Another unexpected job — but another bullet dodged.
What Comes Next
This refit has been far bigger than planned — but worth every hour and every pound. If Bossy Boots is going to carry customers, race offshore, and be part of Navaia’s future, she needs to be safe, strong, and reliable.
Next year we’ll turn to cosmetics:
Cockpit gelcoat
Deck touch-ups
Interior woodwork
Painting the bilge
Her sail wardrobe is growing thanks to generous donations — she now has a No.1, No.2, No.3, No.4, a new Sanders storm jib, and I’m chasing a spinnaker. I may treat her to a new mainsail if budget allows.
If anyone has good second-hand sails (main, genoa, spinnaker), please get in touch.
Looking further ahead, a new engine is on the wish list for 2026, and eventually a windvane for offshore adventures.
Racing plans include Round the Island, Cowes Week, Contessa one-design events, and working towards qualifying races for the 2027 Fastnet.
Commercially, we already have several Round the Island experiences booked, and I’m excited to get people aboard and give them a true, raw adventure on a classic boat with real heart.
If you’re interested, you can learn more or book at:
https://www.navaia.co.uk