The essentials in 30 seconds
- Complete refit of a 40-foot sailboat = 6-10 week project + €25,000-45,000 VAT excluded. Includes main chartplotter + radar + AIS + autopilot + wind transducer + power (lithium bank). Plan during 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 VAT excluded, keep existing autopilot), standard (~€30,000 VAT excluded, full B&G or Raymarine refit), premium (~€45,000 VAT excluded, IRC racing with H5000 Performance + Madintec).
- Typical ROI: 8-12 years (modern electronics lifespan). Also increases resale value by 15-25% on the second-hand market.
- Consistent ecosystem choice is critical. Mixing brands degrades integration. For a 2026 refit, choose Raymarine OR B&G for 60-80% of the equipment; only third-party peripherals (AIS, handheld GPS, antennas) can be mixed.
Replacing 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 one-time user training. This article outlines the Skysat workshop method in 8 steps, with budgeted scenarios.
Related topics: energy refit winter layup (lithium bank), GPS-fishfinder combos (screen size), autopilot B&G vs. Raymarine.
Why a full refit vs. piecemeal upgrades
Four major technical reasons:
- Ecosystem consistency: mixing Raymarine + B&G + Garmin over 10 years degrades integration. A full refit aligns everything.
- Homogeneous wiring: clean NMEA 2000 backbone, consistent cable gauges, matched fuses.
- Economies of scale: installation labor -25 to -35% for a full refit vs. separate upgrades over 5-10 years.
- Clean documentation: up-to-date schematics, retained manuals, single training session for the owner.
Step 1 — Existing system audit
Comprehensive assessment before any material selection:
- Current equipment inventory: brand, model, age, functionality.
- Electrical diagram: retrieve from original builder or redraw.
- Recent failures and owner-perceived limitations (1-2 h interview).
- 24 h power draw measurement with shunt during typical sailing (1-2 weeks).
- Detailed photos of every station (chartplotter, autopilot, batteries, switchboard).
Step 2 — Sizing and ecosystem selection
Based on the audit, key decisions:
- Main ecosystem: B&G (sailboat + racing focus) or Raymarine (versatile cruising). 60-80% of equipment in this ecosystem.
- Chartplotter size: 12" standard for 40-foot sailboats (see GPS-fishfinder article).
- Autopilot: keep existing ram if <10 years or full refit (see ram article).
- Power: lithium conversion if not already done (see lithium plug & play article).
Step 3 — Equipment ordering
Bulk order to optimize lead times and logistics:
- Consolidated 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 1 week:
- Remove old equipment (chartplotter, displays, sensors, batteries).
- Sort: second-hand resale (~30% of new value), electronics recycling, waste.
- Deep clean mounting areas (corrosion, moisture, paint touch-ups).
- Structural checks (mounts, watertightness, hull sections for cable passes).
Step 5 — Hardware installation
Project 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 + fluxgate compass).
- Power: lithium bank + BMS + DC-DC converter + monitoring (see power refit article).
Step 6 — Software integration
Cross-configuration:
- Calibrate sensors (compass, rudder angle, wind, speed, depth).
- NMEA 2000 coupling between all sources (AIS → chartplotter, autopilot ↔ compass).
- Load charts (Navionics+ Raymarine or C-MAP B&G).
- Configure autopilot (modes, gains, polars if available).
- Test BMS, DC-DC, set voltage thresholds.
Step 7 — Commissioning and testing
Final validation 2-3 days:
- Dock test: all displays, all sensors, all communications.
- Engine test (alternator, DC-DC, start-up).
- Splash test and sailing: autopilot at sea, speed-through-water vs. GPS, depth, wind.
- Calibrate VHF antenna VSWR.
- Test ASN/DSC on channel 70.
Step 8 — User training
2-3 sessions with the owner:
- Walkthrough of chartplotter features: charts, fishfinder, AIS, radar, autopilot.
- Emergency procedures: ASN/DSC, EPIRB (if installed), MOB.
- Seasonal maintenance: antifouling fishfinder, sensor cleaning, BMS checks.
- Documentation hand-off: manuals, schematics, service contacts.
3 budget scenarios with cost breakdown
| Item | Light (€18,000 VAT excluded) | Standard (€30,000 VAT excluded) | Premium (€45,000 VAT excluded) |
|---|---|---|---|
| Main chartplotter | Axiom+ 9 (€1,800) | Axiom Pro 12 or Zeus 3S 12 (€3,500) | Zeus 3S 12 + 30/30HV (€5,200) |
| Secondary display | — | 1 × 9" 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 | VHF AIS-RX (V60 = €723) | VHF V60-B AIS Class B (€1,049) | V60-B + GPS-500 (€1,154) |
| Wind transducer | WS320 wireless (€1,499 pack) | WS710 vertical wired (€2,043) | WS720S Ocean spec (€2,865) |
| Autopilot | Keep existing if serviceable | B&G ram T1 + NAC-3 (€3,400) | H5000 CPU Performance + ram (€5,800) |
| Lithium power | 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 VAT excluded | ~€18,000 | ~€30,000 | ~€45,000 |
FAQ — Electronic refit for a 40-foot sailboat
How long does a full refit take?
6-10 weeks dry dock + splash test. Schedule during winter layup (Oct-Mar) to minimize seasonal impact. Pre-order equipment 4-6 months before project start to secure availability and workshop slot.
What is the ROI on a €30,000 VAT excluded refit?
Multiple angles: (1) modern electronics lifespan 8-12 years = annual amortization ~€2,500-3,750; (2) resale value: +15-25% depending on market; (3) usage: modern electronics = increased safety + doubled battery autonomy + transformed onboard comfort. ROI is multidimensional, not purely financial.
Can the refit be done in multiple phases?
Possible but suboptimal. Compromises on ecosystem consistency and integration. Cumulative costs higher (~+20-30% vs. full refit). Only consider if serious budget constraints or if phase 1 requires testing before phase 2.
Does the mast need to be lowered for the refit?
Not mandatory but practical. If the mast is already being lowered for other reasons (paint, rigging inspection), take the opportunity to rewire VHF, wind sensor, GPS antenna. Otherwise, refit can proceed with mast in place using existing cables or new cable runs via masthead.
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 5 years NG). Skysat labor warranty: 12 months. Annual maintenance contract available (~€800 VAT excluded/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 VAT excluded prices are indicative of authorized distributor rates.
