Checklist for a project to
Acquire,  refurbish, and begin sailing a used Lightning sailboat
(assumes you have already decided that a Lightning is the right boat for you)
Activity ID Activity Name Activity Description
1 Acquisition Phase Shop for a boat and negotiate its acquisition.
1.1    Search for a boat Find out about available boats.
1.1.1       Decide on selection criteria Determine price, condition, location, optional equipment, and trade-offs between them, that you want and/or can live with, for hull, spars, rigging, sails, accessories, trailer.
1.1.2       Read classified ads Check available sources, including club newsletters, ILCA publications, and club and ILCA web sites.
1.1.3       Call for information Respond to advertising, arrange to check out candidate boats for acquisition.
1.1.4       Check out boats Go look at candidate boats.
1.1.4.1          Make appointments Call and set up times and places for visit.
1.1.4.2          Get directions Determine how to get to  locations.
1.14.3          Go look at boats Visit boats and check them out.
1.1.4.3.1              First visit Examine boat and equipment and see if it fits your criteria for condition, optional equipment, price and possible trade-offs, to decide if it is worth pursuing.
1.14.3.1.1                 Ask questions Ask about the history of the boat, particularly if it has been repaired after accidents; also whether or not registration and title papers are available and in order (boat and trailer need separate title/registration documents), and whether or not there is a current ILCA measurement certificate.
1.1.4.3.1.2                Check condition Look at general condition of boat, equipment, and accessories, to help decide if boat fits your criteria.  Determine if trailer is roadworthy, and if not, what work is required.
1.1.4.3.1.3                Make decision Decide if boat is worth pursuing, considering asking price, condition, location, accessories.
1.1.4.3.1.4                Inform seller of decision Let seller know that you are interested in pursuing (if you are) or that you are not interested.  If interested in pursuing, arrange for a second visit.
1.1.4.3.2              Second visit Return for a second visit
1.1.4.3.2.1                Arrange for survey Arrange to have an expert in evaluating boat conditions to accompany you on the second visit (Note -- if boat will be insured, the insurance company will want a Marine Survey conducted -- by a registered marine surveyor -- ).
1.4.1.3.2.2               Return to boat with surveyor Bring an expert boat evaluator to look at the boat with you, for the purpose of identifying and evaluating hidden flaws -- rotted fiberglass; waterlogged fiberglass; structural damage; worn rigging, spars, sails, and accessories.
1.1.4.3.2.3               Evaluate boat Using input from the surveyor, determine whether or not to make an offer on the boat.
1.1.4.3.2.4               Make offer If a decision is made to pursue acquisition, make an offer on the boat,
1.1.4.3.2.5               Negotiate price and terms Work with the seller to achieve a win/win settlement regarding price and terms -- include time and location of possession.
1.2    Prepare to take possession Prepare, upon successful completion of acquisition negotiations, take possession at agreed time and place, according to agreed terms.
1.3    Take possession and transport to workshop location Take possession of the boat and transport it to the location where the renovation work will be done.
1.3.1       Arrange for towing of boat on trailer Assuming you don't already have a car equipped to tow the trailer, arrange, with someone who does, to get the boat-on-trailer towed to your workshop location.
1.3.1.1          Check on size of hitch ball required. Find out what size ball the trailer hitch requires -- most likely 2 inch, or possibly 1 and 7/8 inch.
1.3.1.2          Acquire and install the right size ball It's best to find a towing vehicle that already has the right sized ball -- changing balls is difficult, requiring wrenches that can loosen a tightly-torqued nut that is probably also corroded in place.
1.3.1.3          Check on trailer tail light hook-up Confirm that the towing vehicle has an electric receptacle that matches the electric plug and wiring for the trailer tail lights.
1.3.1.4          Check on license plates for trailer Make sure the trailer has current license plates.  If you are towing home a newly-purchased trailer, you can get temporary tags for it, but you can not load the trailer with anything (that includes the boat)  while it is carrying temporary tags!
1.3.1.4.1            Transfer trailer title and get trailer license plate If trailer does not have current license plates, take the bill of sale, and the prior owner's title and registration papers, and go to a DMV office to complete the transfer of title, and register the trailer in your name, and get new plates.  You'll need to do this eventually anyway, but you don't want to be towing a trailer with expired tags, so take care of it now if you need to.
1.3.1.4.2           Transfer boat title, and register boat with VDGIF You won't need to do this until you are ready to put the boat in the water, but since we are thinking about registration now, it's included here.  You'll need the bill of sale and the prior owner's title and registration paperwork -- if they are not available, you'll have to do some extra leg work here to satisfy VDGIF.
1.3.1.4.3          Check with insurer re: towing the trailer Make sure your automobile policy covers you for towing the trailer and boat.
1.3.1.5          Join ILCA and local fleet, notify them of transfer If you are not already a member of ILCA, subscribe now, and let them know of title transfer.  Also, join the local lightning fleet, or change your local fleet membership, if applicable.
1.3.1.6          Put your name on waitlist for slip at marina If you know there is a waitlist for slips at the marina, put your name on it now.
1.3.2       Arrive at boat location with towing vehicle Get set to bring her home.
1.3.3       Inspect trailer and boat for towing readiness Check out the trailer (frame, hitch, tires, wheel bearings, electrical wiring) and the boat (tie-down, cover, loose equipment secured) to ensure it is ready for the trip. Hook up and test the trailer tail lights, brake lights, and turn signals, to ensure they work.  Be prepared to make repairs if they don't.
1.3.4       Obtain and pack all included equipment Obtain sails, rigging, spars, equipment (anchors; life jackets; rudder; tiller; boom crutch, hiking straps, covers; charts; etc. - everything that was included in the deal) and pack for travel.  Make sure everything is secure.
1.3.5       Obtain all needed paperwork Obtain or bring bill of sale, title, registration, measurement certificate, etc.
1.3.6       Find out how to drive with a trailer attached If you are doing the driving, read up on, or ask about towing a loaded trailer with overall length of about 25 feet and weighing about 1,000 pounds.
1.3.7       Transfer funds to seller Pay the seller, remember to say Thank You.
1.3.8       Transport to workshop location Drive it away, drop it at workshop location.
1.3.9       Cover the boat-on-trailer to protect from weather Obtain a heavy-duty 10 X 22 tarp, and shock cords, and use them to protect the boat from weather. 
2 Refurbishing Phase Refurbish boat, trailer, and equipment
2.1    Establish relationships with suppliers Contact potential suppliers of parts, tools, and services, and get copies of  their catalogs,  including local suppliers like Boat U.S.; West Marine; and Annapolis Performance Sailing; plus specialty suppliers such as FabriCraft.
2.2    Establish relationships with refurbishing experts Contact members of the local fleet, and others who have done refurbishing to let them know you'll be asking for advice.
2.3 Research articles and books on refurbishing Use the Internet and other sources of documentation to find articles on refurbishing Lightnings, and read them.
2.4    Obtain a set of plans for Lightning sailboats Contact ILCA and obtain a copy of blueprints for the Lightning sailboat.
2.5    Organize the work site Prepare the work site --space;  lighting; ventilation; tools; electrical outlets; etc.
2.6    Make a cradle (Optional) A lightning will fit in a standard 20' garage if removed from the trailer and placed on a cradle, and the deck will be a bit lower too, making it easier to get in and out of the cockpit.  If this seems like a good idea, make the cradle now.
2.6.1       Draw up plans Use the boat support trusses on the trailer as a template for the cradle support trusses, contoured to fit the bottom of the boat, then design a cradle that can be made from standard 2 x 4 and 2 x 6 framing lumber. 
2.6.2       Obtain lumber, hardware, tools needed Shop for the lumber, hardware, tools needed to make a cradle.  Don't forget materials for cushioning the support trusses (thick plush carpeting is one option), and casters or wheels for the bottom of the cradle.
2.6.3       Build cradle Follow plans to build the cradle.  The finished dimensions will be approximately 8' long by 6' wide by 12" high.
2.6.4       Waterproof cradle Use a branded water sealer, paint, or varnish to protect the finished cradle from the elements.
2.7    Put boat on cradle Transfer boat from trailer to cradle.
2.7.1       Decide if you want to remove the centerboard first Decide if you want to remove the centerboard before placing boat on cradle.  If so, do it now.
2.7.1.1          Remove Centerboard (optional) Remove centerboard
2.7.1.1.1             Disconnect centerboard uphaul Disconnect uphaul from centerboard
2.7.1.1.2             Remove centerboard pin cover plates Remove pin cover plates from centerboard trunk
2.7.1.1.3             Support centerboard from bottom and top Rest the bottom of the board on the trailer axle or cross-brace, and support the top of the centerboard from above, to take weight off the pin.
2.7.1.1.4             Drive centerboard support pin out of hole Tap gently on the pin, using a hammer and nail set or other tool to drive it through the hole in the board trunk.
2.7.1.1.5             Carefully work centerboard up and out of trunk With two strong individuals, lift the board up and out of the board trunk.  Ensure there is enough vertical clearance above the boat - at least five feet above the top if the centerboard trunk.  Be careful to not ram the end of the centerboard into the after end of the trunk on the way up. Note: board weighs as much as 130 pounds.
2.7.1.1.6             Lay centerboard on supports on floor Carefully move the centerboard onto a pair of 4 X 4  posts arranged horizontally to provide support under the board when it lies on the floor.  Don't drop it -- if it lands on the boat deck it can crush it, and if it lands on your foot it could amputate it.
2.7.2       Obtain/construct boat hoisting mechanism One possibility is to obtain a one-ton capacity chain hoist or block-and-tackle, and build/reinforce an attachment point in the ceiling above the boat,  ensuring there is enough vertical clearance for the hoisting mechanism.  Alternately, a team of 8 strong individuals using four eight-foot 4 X 4 posts should be able to lift the boat off the trailer and lower it onto the cradle.
2.7.3        Inspect reinforced attachment point Have a structural engineer or architect inspect and approve the reinforced attachment point in the garage ceiling
2.7.4       Check out hoisting bridle on boat Ensure the hoisting bridle on the boat is in good condition; replace it if it is not.
2.7.5       Hoist boat to remove it from trailer Hoist the boat to lift it from the trailer.
2.7.6       Lower boat onto cradle Lower the boat onto the cradle.
2.8    Plan the refurbishing work Decide what refurbishing is needed and will be done, and how long it should take.  Include trailer, hull, cockpit, rigging, spars, hardware, sails, covers, and other equipment in the refurbishing plan.
2.8.1       Start a "to do" list See example in column B, starting in row 120
2.8.2       Maintain the "to do" list Line out completed items, add new items as you think of them -- I kept mine in the car, as frequently thoughts would appear when driving to/from work.
2.9    Do the refurbishing work - boat Follow your plan to refurbish the boat.  Make multiple trips through this loop below:
2.9.1       Acquire needed materials. Acquire materials
2.9.2       Acquire needed tools. Obtain tools (see example list in column B at row 212)
2.9.3       Obtain advice on how to proceed. Get advice
2.9.4       Refurbish the boat. Do the work
2.10    Reinstall removed hardware and equipment Put the boat back together
2.11    Install DGIF Registration Number on hull Attach Registration number to hull
2.12    Install boat name and other graphics on boat Attach graphics to hull
2.13    Do the refurbishing work - trailer Refurbish, as needed, the trailer frame, wheels, tires, wheel bearings, cushioning, and electrical components.
2.14    Put boat back onto trailer. Put boat on trailer
2.15    Reinstall centerboard (if it was removed) Reinstall centerboard
3 Post-refurbishing phase After refurbishing is complete
3.1    Acquire/Equip a vehicle to tow trailer Get a vehicle that can tow a Lightning on a trailer
3.1.1          Research vehicle towing capabilities Vehicle must be able to tow 1,000 pounds
3.1.2          Acquire vehicle (if necessary) Your current vehicle may already be capable, but, if not, go purchase one.
3.1.3          Equip vehicle for towing If your vehicle is not equipped for towing, get and install a hitch kit and the needed electric receptacle.
3.1.3.1             Obtain hitch kit Some U-Haul stores sell and install hitches.
3.1.3.2             Have hitch kit installed I acquired mine through the Goodyear Auto Service Center, and they installed it.
3.1.3.3              Obtain wiring kit Wiring kits (vehicle end and trailer end) are available at most auto parts stores.  Make sure that the wire is long enough.
3.1.3.4             Install wiring kit. Follow instructions to install the wiring kit, making watertight coverings on the wire splices.
3.1.3.5             Check out installed wiring and hitch. Make sure the hitch and wiring work properly.
3.2    Acquire dry slip at marina Get a slip at marina
3.2.1       Check on status of your name on the waitlist Find out how close you are to top of list
3.2.2       Pay fee (once your name is at the top of the list) Pay the annual fee
3.2.3       Obtain pass Obtain vehicle pass
3.3    Confirm insurance Discuss insurance needs and options with insurance agent -- your homeowner's policy may provide liability coverage, but check out the provisions and limitations, and consider supplemental marine policies too.
3.4    Tow boat to marina Get the boat to the marina
3.5    Learn how to sail a Lightning Read books and articles, enroll in a sailing course, and crew for an experienced skipper to learn the sailing characteristics of a Lightning sailboat
3.6    Learn the rules of water safety Read books and articles, take a water safety course, and otherwise figure out how to be safe on the water
3.6.1       Obtain copy of rules Get rules
3.6.2       Memorize and internalize them. Memorize them
3.6.3       Attend seminars where the rules are explained Understand them
3.6.4       Test your understanding of the rules Take exam
3.7    Learn the Racing Rules of Sailing Read the Racing Rules of Sailing, read books and articles, take a Sailboat Racing course, and otherwise figure out the rules
3.7.1       Obtain copies of rules Get a copy of The Racing Rules of Sailing, downloadable from the WWW - current version is for CY 2001 - 2004
3.7.2       Memorize and internalize them. Memorize them
3.7.3       Attend seminars where the rules are explained Understand them
3.7.4       Test your understanding of the rules Take exam
3.8    Ensure boat has all required safety equipment The boat must have wearable PFDs for each person on board; plus one throwable PFD; a bailing bucket; 
3.9    Obtain Foul Weather Gear Get waterproof jacket, hat, pants, footwear
3.10    Go sailing! Enjoy!
     
Example "to do" list Spare Parts List
 
Adjust tension on standing rigging
Attach carabineer to backstay
Attach ILCA decal
Attach tell-tales
Block trailer wheels
Bring a cigarette lighter (for fusing rope ends)
Bring a flashlight
Bring band-aids
Bring paper towels
Bring rags, newspaper, mineral spirits, acetone
Bring solvent for removing old tape adhesive
Bring string for whipping rope
Bring sunscreen (SPF 45)
Check out mast & standing rigging
Check out sails, repair as needed
Check out the marina
Clean/wax boat bottom
Close the bailer before launching
Confirm rake on mast
Decide on name for boat
Ditch surplus paddles
Do sea trials
Figure out running rigging options
Find leak and plug it
Fix bolt on tiller
Fix rudder lock
Get & install hiking straps
Get a good tire gauge
Get a watertight storage box
Get bladders for flotation tanks
Get boat into garage
Get chart of river
Get compass
Get extra clevis pins and cotters
Get gasket material for inspection ports
Get good PFDs
Get hardware for new hoisting bridle
Get new spinnaker pole
Get new trailer tires
Get other tools for toolbox
Get plugs for built-in flotation tanks
Get popsickle sticks
Get sponges
Get Swiss army knife for tool box
Get tool box
Get trailer repaired
Install mooring cover
Install trailer hitch on car
Make "chicken wire" for middle hiking strap
Make a mooring line
Make additional mast blocks (deck & floor)
Make boom crutch
Make new hoisting bridle
Make support blocks for back of trailer
Order mast cover and rudder cover
Order mooring & trailering covers
Order shirts and caps
Paint coaming
Paint name on boat
Paint the hull
Pull & paint centerboard
Put ID numbers on toolbox, paddles, bailing bucket
Put water seal on drums
Rebuild seats
Re-do existing woodwork
Register boat
Remember to bring bailing bucket
Repaint trailer
Repair boom
Repair centerboard trunk at pin
Repair shroud turnbuckle
Repair trailer tail lights
Replace numbers on spinnaker
Replace running rigging
Replace shock cord on rear tank port cover
Replace spinnaker guy hook rubber gates
Replace spinnaker sheets (50' of 1/4 " cord)
Replace trailer wheel bearings
Re-varnish tiller, rudder, paddles
Rig a centerboard preventer
Rig a jib cloth downhaul
Seal bailer (use Vaseline)
Set up logbook
Step mast and check standing rigging
Tighten/replace screws on mast
Touch up hull paint
Touch up trailer paint
Varnish floor boards
Tools List
 
On-board toolbox (waterproof, sealed):
Band-aids
Compass, hiker's hand-held 2" dia
Cord, nylon braided, 1/8 inch, 30 feet
Cork stoppers, half-inch
Duct tape, small roll
Knife, Swiss Army
Lighter, butane cigarette
Marine adhesive sealant, 3 oz tube
Pliers, needle-nose, 9-inch
Needles, sewing, assorted heavy-duty
Pencil, No 2
Pens, ball point
Quick fastener, spinnaker, spare
Screwdrivers, 9-inch, assorted, 4 
Sticks, popsicle, 6
String, twisted white poly, 150 yds 
Tape cassette, discarded audio (for tell-tales)
Tape, masking, 1 1/2 wide, 10 yards
Thimble
Thread, upholstery
Twine, whipping, no 2 waxed, I reel
Vaseline, 3.75 oz jar
Wire, soft, 16-gague
 
 
In-car toolbox (small, plastic}:
Bits, twist drill, assorted sizes, in case
File, flat, 9-inch
Files, flat, 13-inch, 2
Files, set, miniature 7" assorted, 6
Flashlight, mini-Maglight (2 AA battery)
Pen, ball point
Pencil, no 2
Pliers, channel lock, 9-inch
Pliers, regular, 7-inch
Resin, 2-part epoxy (JB Weld), 1-oz tubes
Screwdriver, 4-inch, 1/4" wide slot
Stopwatch, digital, LCD (inexpensive)
Tape measure, 50-ft
Tension gauge for standing rigging
Tire gauge, good
Wrenches, combination box/end, assorted, 7
 
 
 
 
Garage toolbox (big, metal):
Awl, punch
Awl, scratch
Bits, power wood, assorted, 6
Bits, twist drill, assorted sizes
Chisels, wood, 3/8 and 5/8 wide blades, 8-inch
Knife, utility, w spare blades
Pliers, channel lock, 11-inch
Pliers, vise-grip, 9-inch
Screwdriver, ratchet offset, 4-inch, w bits
Tape measure, steel, 16 ft.
Twist drill, hand, small
 
Workbench tools
Blade, drywall finishing
Block, sanding, hand
Clamps, C, 3 (medium, large, extra-large)
Clamps, quick, 12-inch, 2
Crimping tool, wire connector, 12-inch
Cutters, wire, 12-inch
Drill press (neighbor's)
Drill, electric, cordless
Gun, caulking
Gun, staple, hand-powered
Knife, putty
Level, bubble, 9-inch
Level, spirit, 24-inch
Plane, block, 6-inch
Rasp, wood, 12-inch
Riveter, blind, 12-inch
Sander, belt, electric
Sander, orbital, electric
Sandpaper, assorted grades
Saw, back, w 18-inch blade
Saw, circular, electric
Saw, hack, w 12-inch blade
Saw, keyhole, w 18-inch blade
Saw, sabre, electric, small
Screwdriver, cordless electric, w bits
Square, 12-inch adjustable
Square, carpenter's
Stripper, wire insulation, 8-inch
Wrenches, crescent, 6-inch and 8-inch
Wrenches, socket, set