‘But the Wisting project has been a special challenge, raising the bar in all areas, said BWK’s managing director, Chris Baker. ‘She’s the biggest project for the yard in 40 years, certainly the most sophisticated. We didn’t just provide space on the slipway.’

Baker, a naval architect and one of the four who bought the yard in 2003, has been responsible for virtually all of the technical design of the new Wisting, which retained only its original hull and main deck.

Built in steel to Ice Class Rules 1978, HM5 was decommissioned in 2004, sold to its present owner and delivered to the Isle of Man where it was hauled on BWK’s No. 1 slipway. Once the hull was assessed in detail and the ultimate design finalized, the conversion began.

BWK started by removing Wisting’s superstructure along with 50% of the deck and the transom stern. The vessel was then gutted of all mechanicals with the exception of the rudder and steering gear. One watertight bulkhead was then moved and new double bottom tanks were fabricated. The stern was replaced with a canoe stern which had been modeled by and fabricated on site by BWK.

Wisting’s new superstructure was also designed by BWK. Chris Baker then approached Mustang Marine (Wales) Ltd, which produced CNC data and fabricated an aluminium alloy structure which comprised the wheelhouse and upper deck. Mustang had recently acquired the ‘Ship Constructor’ ship design software and the Wisting project provided an excellent opportunity for the Mustang technical team to add it to their existing expertise in modeling and kitting.

The completed assembly was loaded out from Mustang’s yard directly to the coaster ‘Silver River’, operated by Ramsey IoM based Mezeron Ltd, which delivered it to the BWK yard where it was welded in place using Tri-plate joining strip.

A new funnel not only provides an outlet for machinery space ventilation but also houses a wet bar. It was designed and fabricated by BWK as was the galley and virtually all stainless steel in the vessel.

 BWK installed two Caterpillar diesel engines providing power to the 400kW electric motor which drives the new 1.5m single screw via a new 100mm shaft. A unique 360(DEGREE) 100kW HRP electric bow thruster was installed, reducing the space required inside the vessel compared to a tunnel or retractable thruster. This unit gives Wisting a ‘get home’ capability and also enables it to take the ground. The stern gear, gearbox and propeller were all supplied by Kort Propulsion.

In partnership with BWK, Seaking Electrical Ltd was asked to project manage the electrical design and installation, liasing with suppliers and their engineers to produce a fully integrated electrical package. The 400kW electrical variable speed drive module at its heart was chosen for its very low harmonic distortion. By using an 18 pulse drive, the associated harmonic signature is such that the generators can be sized in accordance with the amount of power required, meaning no power is wasted. The system is fully automated to provide different methods of operation, including dynamic positioning. The DP facility is enhanced by the variable speed bow thruster.

Electrical equipment on the high tech bridge includes touch screen controls of the vessel’s three gensets and switchboard power distribution via a fully automated power management system. There is safety management of the vessel’s protection and monitoring systems as well as the engine, tank, bilge and ballast, all via the user friendly touch screen. Wisting is also provided with security motion detection surveillance cameras and infrared gangway control.

Auxiliary electric power is generated by a new Northern Lights 100kW diesel genset and Niad zero speed stabilizers. In the style of many modern cruise ships, Wisting’s main engine generators, main engine, auxiliary generator and bow thruster are connected by a single bus. The electrical design and installation was carried out in accordance with MCA regulations and was subject to the Lloyds classification of the Isle of Man registered craft.

The transformation of Wisting would not have been complete without a galley equipped to produce fine cuisine. At the heart of the kitchen for an expedition yacht are food storage facilities. Penguin Refrigeration was employed to design and supply the stainless steel catering refrigeration and freezer systems built by Italy’s Frigoboat. Some 1,250 litres of space was supplied in total. For maximum flexibility, the 500 litre freezer is also able to run as a refrigerator, with precise temperature control from -22(DEGREE)C to +10(DEGREE)C. The units were designed to provide maximum storage within the space available, chilled by a multi-compressor, water cooled system which allows full back-up and the most efficient energy consumption. Fresh water is produced by a Seafresh desalinator reverse osmosis unit.

Casse Tete Marine of Hamble was also a major contributor to Wisting, building a traditionally styled 21’ launch/tender to the owner’s specification, featuring teak decks and wood trim. The versatile yard also manufactured all the shower and wet room bays, vanity units and tops for all the bathrooms, overheads for the wheelhouse and all side decks and even the bulwark doors.

With the hull finished with AwlGrip on International epoxy fairing and the July relaunch date drawing close, detailed planning was made for the event. In meetings between Chris Baker, Captain Frank Hilgevoord and Isle of Man pilot Captain Stephen Carter of Laxey Towing Co Ltd, two main criteria emerged. One was that Wisting should be launched effectively as a dead ship as BWK engineers wanted time to check and bleed all systems. It was also determined that all towage should be undertaken in towing mode to protect the quality finish of the hull.

Because of the restricted nature of Ramsey Harbour the Laxey Towing workboats ‘Girl Mary’ and ‘Lonan’ were used instead of larger tugs and tasked with taking charge of Wisting and towing it to an anchorage in Ramsey Bay. The forward planning paid off, as the launch and tow went without a hitch, with Captains Hilgevoord and Carter controlling operations from on board Wisting.

With the vessel successfully relaunched, BWK has demonstrated its extended capabilities to not only build rugged workboats but to manage far bigger projects. The yard is currently looking for another conversion to take on.