A restoration project on a Salthouse 65 revitalised its profile and interior spaces, revamping the look with a modern window system and transforming this sturdy ocean-going cruiser into a head-turning vessel once more.
The 2006 New Zealand-built Salthouse flybridge cruiser named “Phantom” appealed to its current owner for its classic lines and “good bones”, along with the brand’s reputation for seaworthiness.
A former motor mechanic, the Perth-based owner saw the potential immediately and bought the boat in October 2024. To give it the tender-loving-care it required and to bring it into the modern era, he entrusted Phantom to the experts at The Boat Works.
A seasoned boat owner, he plans to cruise the west coast and Rottnest Island with his family – two children and four grandchildren. But first, the objective is to cruise from the Gold Coast to Townsville and “over the top” to Perth.
“We were drawn to the boat because of the Salthouse reputation for built quality and it fulfilled our requirements perfectly,” he said.
“All it needed was a refurbishment to bring it back to as-new condition.”
In addition to the upholstery, carpet and teak, the aluminium window frames needed immediate attention.
“The frames were starting to corrode with age and leakage. The previous owners had drilled into the frames to fit shutters and water had leaked in, causing corrosion. I was not satisfied with the condition nor the appearance.”
He had seen restorations of framed windows, but once he consulted with the glass experts at Integ Marine Group, the brief changed.
“His first inclination was to retain and restore the windows, but they had aged to the point where they had to be replaced,” explained Darren Dench, Managing Director at Integ Marine, internationally renowned specialists in marine glazing.
“We wanted to be true to the Salthouse aesthetic and respect the quality of the build, so we came up with an alternative that would honour the brand’s heritage and give the boat a modern look.
“The solution was to move to direct glazing, a modern window system that would not only make the boat look better, but work better as well. In future, the windows won’t have corrosion problems,” added Darren.
The system involves recessing the section where the windows are bonded so that the glazing sits flush with the curved superstructure of the boat. This enhances the shape of the boat and opens up the interior, specifically the saloon and flybridge.
Darren and the team at Integ designed templates for nine window panels in total, using high-spec glass rated for offshore cruising.
The original aluminium frames consisted of a series of mullions which divided the windows and obscured the view. A naval architect was consulted to design mullions that would add support and structure without impediment.
Before any glass could be installed, the talented craftspeople at O’Neill’s Shipwrights were called upon to apply their expertise to what was a complex and challenging job.
“Recessing the glass into the superstructure of the boat is quite a task,” commented Andy O’Neill, Director.
“It was built to suit the original windows. So, taking Integ’s templates, we lofted out the proposed glass locations, cutting through the superstructure – which meant adding temporary posts to the support the flybridge. The naval arch designed compression posts and window mullions to support the flybridge structure from the main deck.
“Then we had to fabricate composite compression posts into the superstructure and create a composite rebate to house the new glass panels. That way, looking from the outside, the glass is flush, creating a slick, contemporary profile.
“We also modified the interior pelmets and timber shelving to line up perfectly with the windows inside,” added Andy, whose notes show they spent 500 hours on this aspect of the project.
Pat Menner, Operations Manager at O’Neill’s at The Boat Works commented, “Outside, the new windows follow the shape of boat and add a dynamism to the profile. Inside, the ceramic black outlines around the window perimeters finish in line with the upholstery and cabinetry to create a seamless look – like frameless windows for a clean finish.”
We then engaged with a Marine Coatings specialist to repair the paint work on the superstructure where all the works joined.
The project took 10 weeks from client approval to completion and return to water, and the results speak for themselves.
“It looks amazing!” said the ecstatic owner. “The window refurbishment has changed the look completely. From the outside, the profile is slick. Inside, the interiors are light and bright and the saloon feels more spacious.”
Commenting on the quality of trades and services at The Boat Works, the owner said “The Boat Works’ facilities are incredible.
“They have exceptional trades on-site with world-class expertise. Integ and O’Neills were excellent and their communication was great throughout the entire process. There’s a real pride in craftsmanship which inspires confidence at every stage.”
Darren Dench at Integ Marine praised the vision and collaboration of the owner, saying “He did everything right.
“From the start, he was committed to doing everything properly. The brief changed, but sticking to what was right for the boat ensured a smooth project and impeccable results. O’Neill’s are phenomenal to work with, and the standard of their work is second to none.”
O’Neill Shipwrights has NSW headquarters at Sydney Superyacht Marina in Rozelle and Warriewood on the Northern Beaches, as well as a Queensland workshop at The Boat Works on the Gold Coast, and they are involved in projects all along the east coast.
Integ Marine’s Headquarters and Quality Control Facility is located at The Boat Works on the Gold Coast. They recently established mobile operations in Sydney to service customers throughout NSW and service vessels located anywhere in Australia and internationally.
They will be exhibiting at the 2025 Sanctuary Cove International Boat Show, 22 to 25 May, within the AIMEX Pavilion.
theboatworks.com.au
marinewindowservices.com.au
oneillshipwrights.com.au
