The essentials in 30 seconds
- Complete refit of a 40-foot sailboat = 6-10 week project + €25,000-45,000 ex. VAT. Includes main display + radar + AIS + autopilot + wind transducer + power (lithium bank). Plan during the 2026-2027 winter layup 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, full B&G or Raymarine refit), 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 second-hand market.
- Consistent ecosystem choice 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.
Completely overhauling the electronics on a 40-foot sailboat in a single operation is more cost-effective and higher-performing than piecemeal upgrades spread over 5-10 years. Consistent ecosystem, uniform updates, optimal integration, and consolidated user training. This article outlines the Skysat workshop method in 8 steps, with cost breakdowns per scenario.
Related topics: energy refit for winter layup (lithium bank), GPS-fishfinder display size (9 vs. 12 inch), 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 allows alignment across all systems.
- Uniform cabling: clean NMEA 2000 backbone, consistent cable gauges, matched fuses.
- Cost savings: installation labor -25 to -35% with a full refit vs. separate upgrades over 5-10 years.
- Clean documentation: up-to-date schematics, preserved manuals, consolidated client training.
Step 1 — Audit of existing systems
Comprehensive baseline before any equipment selection:
- Inventory of current equipment: brand, model, age, functionality.
- Electrical schematic: obtain from original builder or redraw.
- Recent failures and owner-perceived limitations (1-2 hour interview).
- 24-hour power draw measurement with shunt during typical sailing (1-2 weeks).
- Detailed photos of each station (display, autopilot, batteries, switch panel).
Step 2 — Sizing and ecosystem selection
Based on the audit, key decisions:
- Primary ecosystem: B&G (sailboat racing focus) or Raymarine (versatile cruising). 60-80% of equipment within this ecosystem.
- Display size: 12-inch standard for 40-foot sailboats (see display article).
- Autopilot: keep existing hydraulic ram if <10 years old 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 order placement (limited winter capacity).
- "Consumables" list: cables, fuses, connectors, etc.
Step 4 — Disassembly and preparation
Dry yard work: 1 week
- Remove old equipment (display, screens, sensors, batteries).
- Sort: resell used (~30% of new value), recycle electronics, dispose of waste.
- Deep clean mounting locations (corrosion, moisture, paint touch-ups).
- Check structural integrity (mounts, watertightness, hull sections for cable passes).
Step 5 — Hardware installation
Workshop time: 2-3 weeks
- Run cables up the mast (display, VHF antenna, wind sensors, GPS).
- Install NMEA 2000 backbone (see NMEA 2000 article).
- Mount main display at helm, secondary screens, remote controls.
- Install autopilot (ram + computer + rudder angle sensor + compass).
- Power: lithium bank + BMS + DC-DC converter + monitoring (see energy refit article).
Step 6 — Software integration
Cross-system configuration:
- Calibrate sensors (compass, rudder angle, wind, speed, depth).
- NMEA 2000 integration 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 screens, all sensors, all communications.
- Engine test (alternator, DC-DC, starter).
- Water test and sailing: autopilot at sea, speed-through-water vs. GPS, depth, wind.
- Calibrate VHF antenna SWR.
- Test DSC on channel 70.
Step 8 — User training
2-3 sessions with the owner:
- Tour of display features: charts, fishfinder, AIS, radar, autopilot.
- Emergency procedures: DSC, EPIRB (if installed), MOB.
- Seasonal maintenance: antifouling fishfinder, sensor cleaning, BMS check.
- Documentation delivered: manuals, schematics, service contacts.
3 budget scenarios with cost breakdowns
| Item | Light (€18,000 ex. VAT) | Standard (€30,000 ex. VAT) | Premium (€45,000 ex. VAT) |
|---|---|---|---|
| Main display | Axiom+ 9 (€1,800) | Axiom Pro 12 or Zeus 3S 12 (€3,500) | Zeus 3S 12 + 30/30HV (€5,200) |
| Secondary display | — | 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 | VHF AIS-RX (V60 = €723) | VHF V60-B AIS Class B (€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 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 ex. VAT | ~ €18,000 | ~ €30,000 | ~ €45,000 |
FAQ — Electronic refit for a 40-foot sailboat
How long does a full refit take?
6-10 weeks in the yard (dry + wet). Plan during winter layup (Oct-Mar) to minimize seasonal impact. Pre-order 4-6 months before starting to secure material availability and workshop slot.
What is the ROI on a €30,000 ex. VAT refit?
Multiple angles: (1) modern electronics lifespan 8-12 years = annual depreciation ~€2,500-3,750; (2) resale value: +15-25% depending on market; (3) usage: modern electronics = enhanced 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). Consider only under 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 is being lowered for other reasons (paint, rigging inspection), take the opportunity to rewire VHF, wind sensor, GPS antenna. Otherwise, refit is possible with mast in place using existing cable runs or new cabling 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 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 distributor quotes.
