Sideways is not a direction anyone wants a refit to take, yet it’s a familiar outcome on many projects. Owners looking to update their boats—whether for small improvements or complete overhauls—often run into avoidable problems. Experts from three well-regarded Maine shipyards—Lyman-Morse, Front Street Shipyard and Brooklin Boat Yard—say many of these issues stem from choosing the wrong facility or failing to plan and communicate effectively from the start.
“It’s very important to build a relationship with the yard that’s doing the work,” says Eric Beckman, service manager at Lyman-Morse in Thomaston. “Some owners simply hand over a list and return in August, and that’s fine. But if you take a vested interest in the project and work closely with the yard, the results will usually be better.”
Below are the yards’ top recommendations for avoiding headaches during a boat refit, whether the scope is cosmetic or comprehensive.
Shop Around
Selecting the right shipyard is the most important decision you’ll make. The goal isn’t simply to find a yard capable of the work; it’s to find one where you feel comfortable and confident the job will be done properly.
“Visit yards in person,” advises Nick Bellico, service manager at Brooklin Boat Yard. “Walk the facility, meet the team, and watch the crew at work. Those observations tell you much about morale, workmanship and communication. If you’re escorted straight into an office and only allowed to speak with one person, that can be a red flag that you won’t be prioritized.”
JB Turner, president of Front Street Shipyard, suggests narrowing options on paper first, then visiting two or three top candidates. “Shopping more than five yards gets confusing,” he says. “Pick two or three reputable yards to visit and compare.”
Smaller vessels often move around the yard and use various departments, while larger boats typically need a dedicated team and specific facilities. “For a 50- or 60-footer, overhead clearances and beam concerns can be limiting, so the yard needs to plan where and how to stage the work,” Beckman explains. Choosing a yard with the right infrastructure and project-management approach for your boat’s size will reduce delays and surprises.
Have “The Talk” Early
After you pick a shipyard, schedule a detailed conversation about how you use the boat, what you want to achieve, and how much you’re prepared to spend.
“My first questions are meant to understand the owner,” Bellico says. “Are you a day cruiser, a coastal cruiser, do you take kids offshore—what’s the boat’s intended use? That helps gauge scope and cost, and I try to give owners a ballpark number early on.”
Bellico stresses a practical mindset: a refit is not an investment that will be recouped on resale. “Refitting rarely returns your money when you sell. Make the decision because you plan to keep and enjoy the boat for years, not because you expect to break even.” Turner echoes that point: “Boats aren’t appreciating assets. If you love boating and plan to keep your vessel, spending on comfort and safety makes sense. But don’t expect to get the money back at sale.”
Budget conversations should happen upfront, even if only as a rough estimate. “If you don’t at least talk about finances early, it can feel like a bait-and-switch later,” Beckman says. Both owner and yard need clear expectations to avoid blown-up work orders and strained relationships.
Expect the Unexpected
Wish lists are useful, but realistic work plans and contingency funds make refits more predictable. “There’s always something that comes up,” Turner warns. “Build an extra 10 to 15 percent into your budget for surprises.”
Bellico recommends a 10 to 20 percent contingency above initial estimates. “Refits are custom work. Change engines and you’ll likely uncover carpentry, paint or electrical issues nearby. There’s a domino effect you can’t fully predict until the job starts.”
Beckman adds that owners are sometimes surprised when yards recommend replacing components rather than repairing them. Disassembly required for diagnosis can reveal additional damage, and reassembly may not restore original integrity. “We often recommend replacement because it’s more cost-effective in the long run,” he says. Attempting a repair first and then replacing it later can double the cost.
Communicate Constantly
Staying involved throughout the project is one of the best ways to avoid costly misunderstandings. Be reachable by phone, email or text, and visit the yard regularly. “Don’t be afraid to check in,” Beckman advises. “You’re entrusting the yard with something important. You should feel comfortable contacting the manager or yard staff directly.”
Active owner participation also helps the yard move faster and make better decisions. “If something comes up, it’s much easier to Facetime or text the owner with photos and quick questions,” Beckman says. Simple, timely approvals keep the project moving and reduce downtime.
Being on-site helps owners understand the true scope of certain tasks. For example, paint or teak deck work often carries its biggest cost in removing and reinstalling deck hardware, not in the materials themselves. “It’s better to remove every piece of hardware than to paint around it and risk hard paint lines that could fail,” Beckman explains. What looks like a modest material cost can be multiplied by hundreds of labor hours for removal, bedding and re-fastening.
Bellico notes that engaged owners become better stewards of their boats: “The more you visit and learn during the refit, the more prepared you’ll be to operate and maintain the systems afterwards.”
If communication breaks down or work quality deteriorates, owners have every right to pause the project and seek an independent opinion. Turner recommends stopping the job and bringing in a surveyor if estimates are wildly exceeded or workmanship is poor. And after launch, he advises staying nearby for a few weeks to work out any post-refit issues. “Launching and leaving immediately often leads to problems. Cruise locally first so you can identify and fix bugs while the yard is accessible.”
January 2025