The essentials in 30 seconds
- Complete refit of a 40-foot sailboat = 6-10 weeks of work + €25,000-45,000 ex. VAT. Includes main chartplotter + radar + AIS + autopilot + wind transducer + energy (lithium bank). Plan for winter layup 2026-2027 now.
- 8-step workshop method: existing system audit, sizing, brand selection, equipment ordering, disassembly, installation, software integration, final commissioning.
- 3 budget scenarios: light (~ €18,000 ex. VAT, keep existing autopilot), standard (~ €30,000 ex. VAT, complete refit with B&G or Raymarine), premium (~ €45,000 ex. VAT, IRC racing with H5000 Performance + Madintec).
- Typical ROI: 8-12 years (modern electronics lifespan). Also increases resale value by 15-25% on the used market.
- Choosing a consistent ecosystem is critical. Mixing brands degrades integration. For a 2026 refit, choose Raymarine OR B&G as the primary system (60-80% of equipment); only third-party peripherals (AIS, handheld GPS, antennas) can be mixed.
Overhauling all electronics on a 40-foot sailboat in one operation is more cost-effective and higher-performance than piecemeal upgrades over 5-10 years. Consistent ecosystem, uniform updates, optimal integration, and single-session user training. This article describes the Skysat workshop method in 8 steps, with budgets by scenario.
Related topics: energy refit winter layup (lithium bank), GPS-fishfinder combos (screen size), autopilot B&G vs. Raymarine.
Why a complete refit vs. piecemeal upgrades
Four major technical reasons:
- Ecosystem consistency: mixing Raymarine + B&G + Garmin over 10 years degrades integration. A complete refit allows alignment.
- Uniform wiring: clean NMEA 2000 backbone, consistent cable gauges, consistent fuses.
- Cost savings: installation labor -25 to -35% with a complete refit vs. separate upgrades over 5-10 years.
- Clean documentation: up-to-date schematics, retained manuals, single training session for the owner.
Step 1 — Audit of existing systems
Comprehensive assessment before any equipment selection:
- Inventory of current equipment: brand, model, age, functionality.
- Electrical schematic: obtain from the original builder or redraw.
- Recent failures and owner-perceived limitations (1-2 h interview).
- 24-hour consumption measurement with a shunt during typical sailing (1-2 weeks).
- Detailed photos of each station (chartplotter, autopilot, batteries, switchboard).
Step 2 — Sizing and ecosystem selection
Based on the audit, key decisions:
- Primary ecosystem: B&G (sailing + racing focus) or Raymarine (versatile cruising). 60-80% of equipment in this ecosystem.
- Chartplotter size: 12-inch standard for a 40-foot sailboat (see GPS-fishfinder article).
- Autopilot: keep existing ram if <10 years old or opt for a complete refit (see ram article).
- Energy: lithium conversion if not already done (see lithium plug & play article).
Step 3 — Ordering equipment
Bulk order to optimize lead times and logistics:
- Cumulative quotes from 1-2 distributors (Skysat, Mister Marine, Defender, etc.).
- Manufacturer lead times: Raymarine 2-4 weeks, B&G 3-6 weeks, MG Energy 8-12 weeks.
- Book workshop slot immediately after ordering (limited winter capacity).
- "Consumables" list: cables, fuses, connectors, etc.
Step 4 — Disassembly and preparation
Dry dock for 1 week:
- Remove old equipment (chartplotter, displays, sensors, batteries).
- Sort: sell used (~30% of new value), recycle electronics, dispose of waste.
- Deep clean mounting locations (corrosion, moisture, paint).
- Check structure (mounts, watertightness, hull sections for cable passes).
Step 5 — Hardware installation
Workshop for 2-3 weeks:
- Run cables up the mast (chartplotter, VHF antenna, wind sensors, GPS).
- Install NMEA 2000 backbone (see NMEA 2000 article).
- Mount main chartplotter at the helm, secondary displays, remote controls.
- Install autopilot (ram + computer + rudder angle sensors + compass).
- Energy: lithium bank + BMS + DC-DC converter + monitoring (see energy refit article).
Step 6 — Software integration
Cross-configuration:
- Calibrate sensors (compass, rudder angle, wind, speed, depth).
- Link NMEA 2000 sources (AIS → chartplotter, autopilot ↔ compass).
- Import charts (Navionics+ Raymarine or C-MAP B&G).
- Configure autopilot (modes, gains, polars if available).
- Test BMS, DC-DC converter, set voltage thresholds.
Step 7 — Commissioning and testing
Final validation over 2-3 days:
- Dock test: all displays, all sensors, all communications.
- Engine test (alternator, DC-DC converter, start-up).
- Water test and sailing: autopilot at sea, speed-through-water vs. GPS, depth, wind.
- Calibrate VHF antenna SWR.
- Test ASN/DSC on channel 70.
Step 8 — User training
2-3 sessions with the owner:
- Tour of chartplotter features: charts, fishfinder, AIS, radar, autopilot.
- Emergency procedures: ASN/DSC, EPIRB (if installed), MOB.
- Seasonal maintenance: antifouling fishfinder, sensor cleaning, BMS check.
- Documentation provided: manuals, schematics, after-sales contacts.
3 budget scenarios with pricing
| Item | Light (€18,000 ex. VAT) | Standard (€30,000 ex. VAT) | Premium (€45,000 ex. VAT) |
|---|---|---|---|
| Main chartplotter | Axiom+ 9 (€1,800) | Axiom Pro 12 or Zeus 3S 12 (€3,500) | Zeus 3S 12 + 30/30HV (€5,200) |
| Secondary chartplotter | — | 1 × 9-inch repeater | 1 × Axiom Pro 9 or Vulcan 9 R (€2,000) |
| Radar | — | Quantum 2 or HALO20+ (€2,000) | HALO24 or Fantom 24 (€3,200) |
| AIS | AIS-RX VHF (V60 = €723) | V60-B Class B VHF AIS (€1,049) | V60-B + GPS-500 (€1,154) |
| Wind transducer | WS320 wireless pack (€1,499) | WS710 vertical wired (€2,043) | WS720S Ocean spec (€2,865) |
| Autopilot | Keep existing if adequate | B&G T1 ram + NAC-3 (€3,400) | H5000 Performance CPU + ram (€5,800) |
| Lithium energy | 200 Ah Smart pack (€2,200) | 200 Ah pack + Lynx Smart BMS (€3,400) | 300 Ah pack + MultiPlus + solar (€8,500) |
| Labor | ~ €4,000 | ~ €7,000 | ~ €12,000 |
| TOTAL ex. VAT | ~ €18,000 | ~ €30,000 | ~ €45,000 |
FAQ — Electronic refit for a 40-foot sailboat
How long does a complete refit take?
6-10 weeks in dry dock + wet testing. Plan for winter layup (Oct-Mar) to minimize seasonal impact. Pre-order equipment 4-6 months before starting the workshop to secure availability and a slot.
What is the ROI on a €30,000 ex. VAT refit?
Multiple angles: (1) modern electronics lifespan 8-12 years = annual amortization ~ €2,500-3,750; (2) resale value: +15-25% depending on the market; (3) usage: modern electronics = increased safety + doubled battery autonomy + transformed onboard comfort. ROI is multidimensional, not just financial.
Can the refit be done in multiple phases?
Possible but suboptimal. Compromises on ecosystem consistency and integration. Cumulative costs higher (~ +20-30% vs. complete refit). Only consider if serious budget constraints or if phase 1 requires testing before phase 2.
Is it necessary to lower the mast for the refit?
Not mandatory but practical. If the mast must be lowered for other reasons (painting, rigging inspection), take the opportunity to rewire VHF, wind sensors, GPS antenna. Otherwise, the refit can be done with the mast in place using existing cable runs or capelage.
What warranty applies after a Skysat refit?
Manufacturer warranty on equipment: 2-5 years depending on brand (Raymarine 2 years, B&G 2 years, Garmin 2 years, Victron NG 5 years). Skysat labor warranty: 12 months. Annual maintenance contract available (~ €800 ex. VAT/year) for full preventive service.
Skysat operates an integrated workshop in Carnac (Brittany) with 4 teams specialized in sailboat refits. This article reflects our standard method applied to 50+ refits of 40-45 foot sailboats 2022-2026. 2026 ex. VAT prices are indicative of authorized distributor rates.
