The essentials in 30 seconds
- Full refit of a 40-foot sailboat = 6-10 week project + €25,000-45,000 VAT excluded. Includes main display + radar + AIS + autopilot + anemometer + energy (lithium bank). Plan for winter layup 2026-2027 now.
- 8 workshop method steps: 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 used market.
- Consistent ecosystem choice is critical. Mixing brands = integration loss. 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 one operation is more cost-effective and higher-performing than piecemeal upgrades over 5-10 years. Consistent ecosystem, uniform updates, optimal integration, and user training all in one go. This article outlines the Skysat workshop method in 8 steps, with costed budgets per scenario.
Related topics: energy refit for winter layup (lithium bank), GPS-fishfinder display (screen size), autopilot: B&G vs. Raymarine.
Why a full refit vs. piecemeal upgrades
Four major technical reasons:
- Consistent ecosystem: mixing Raymarine + B&G + Garmin over 10 years = degraded integration. A full refit allows everything to be aligned.
- Uniform cabling: clean NMEA 2000 backbone, consistent cable gauges, consistent fuses.
- Economies of scale: installation labor costs -25 to -35% for a full refit vs. separate interventions over 5-10 years.
- Proper documentation: up-to-date schematics, retained manuals, single training session for the owner.
Step 1 — Audit of existing systems
Complete assessment before any material 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 hour interview).
- 24-hour consumption measurement with a shunt during typical sailing (1-2 weeks).
- Detailed photos of each station (display, 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.
- Display size: 12-inch standard for 40-foot sailboats (see display article).
- Autopilot: keep existing ram if <10 years old; otherwise full refit (see ram article).
- Energy: 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 as soon as order is placed (limited winter capacity).
- "Consumables" list: cables, fuses, connectors, etc.
Step 4 — Disassembly and preparation
Dry yard work: 1 week
- Remove old equipment (displays, screens, sensors, batteries).
- Sort: resell used (~30% of new value), recycle electronics, dispose of waste.
- Deep clean mounting locations (corrosion, moisture, paint).
- Check structural integrity (mounts, watertightness, hull sections for cable passes).
Step 5 — Hardware installation
Workshop time: 2-3 weeks
- Run cables in the mast (main display, VHF antenna, wind sensors, GPS).
- Install NMEA 2000 backbone (see NMEA 2000 article).
- Mount main display at the helm, secondary screens, 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: 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-over-ground vs. GPS, depth, wind.
- Calibrate VHF antenna VSWR.
- Test ASN/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: ASN/DSC, EPIRB (if installed), MOB.
- Seasonal maintenance: antifouling for transducer, sensor cleaning, BMS check.
- Documentation delivered: 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 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 | AIS-RX VHF (V60 = €723) | V60-B AIS Class B VHF (€1,049) | V60-B + GPS-500 (€1,154) |
| Anemometer | WS320 wireless pack (€1,499) | WS710 vertical wired (€2,043) | WS720S Ocean spec (€2,865) |
| Autopilot | Keep existing if functional | 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 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 yard + water work. Plan for winter layup (Oct-Mar) to minimize seasonal impact. Pre-order 4-6 months before workshop start to secure material availability and slot.
What is the ROI on a €30,000 VAT excluded refit?
Multiple angles: (1) 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 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. 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 (painting, rigging inspection), take the opportunity to redo VHF cabling, wind sensor, GPS antenna. Otherwise, refit is possible with 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 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 specializing 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.
