The 2004 AGM appointed Robert Brooke as a Zephyr builder. The ZOA is committed to making the Zephyr available to the next generation of New Zealand sailors, but to do this we need to ensure a supply of boats that replicate the “look and feel” of Des Townson’s original design. We expect our relationship with Robert Brook will be an important part of the Zephyr’s future.

The ZOA’s “Re-design” sub-committee of, Don Currie, Russell Turner and myself have given considerable thought on the best way to proceed. We feel the “deliverables” from the building programme need to be

1. Construction of a mould for building the hulls that has sufficient internal rigidity to prevent it from deforming if re-located.
2. Construction of a constraining jig to hold the hull shape while stabilising deck beams and bulkheads are installed.
3. The ZOA will pay for the materials to construct the jigs, and will arrange for the necessary CAD output to facilitate the project. It will retain ownership of these items.
4. Verification of plans and templates for key construction components. The Zephyr has been re-drawn in AutoCAD, but there may be some aspects of the design that we have over-looked or misinterpreted. The CAD derived templates may also need to be checked.
5. Construction of an initial “prototype” hull, which will be for Robert Brooke’s own use. The ZOA has purchased veneer for 5-6 boats, sourced from Christchurch.
6. Building instructions and fabrication recommendations - a set of instructions, tips and tricks that allow subsequent builders to achieve the same result. This “intellectual property” would also belong to the ZOA.
7. Recommendations to the ZOA on potential refinements to construction. There are some common problems in the existing boats. The timber in the transoms and centrecases is prone to splitting and leaking. These elements may be better in plywood, but a suitable design needs to be arrived at. Cracking along the seams of the planks in the outer skin is also a feature of the boats. Support under the side decks where the skipper sits needs to be generous.
8. An indicative price that reflects likely commercial construction costs.
9. Target weights for key stages of construction.  An undecked hull should probably weigh around 42kg, with a decked hull at 51kg. Fittings usually weigh 2.5kg, with a similar allowance for paint. It is important that the boats do not exceed the class minimum weight. It would be a bonus if the finished hull could be sheathed in fibreglass without going over weight, for those that prefer this style of finish.
10. Succession plan for ongoing building. Robert Brooke won’t want to be a Zephyr builder for ever, so it would be good to have documented “production” methods and some orders to hand on to a successor .  The appointment of additional builders, probably in the South Island, may require a second mould. This would be driven by a minimum number of orders (yet to be established) to warrant the investment.
11. The building stage has traditionally been an undecked hull, but we suspect that nowadays most customers will probably want a decked version.
12. Any other comments or recommendations that would help the Zephyr class prosper.

As of October 2008, 20 new boats have been ordered.

The ZOA is committed to the success of this project and will endeavour to provide all practical assistance. Any problems encountered along the way will be resolved in spirit of co-operation and good humour! We are all hoping to learn something and have some fun along the way.

Rob Ebert