We started out looking for a larger boat from our custom Cal 2-30 in the fall of 2008.  We were originally drawn toward a Freedom 39 Pilot house schooner.  Do to a yacht broker breakdown we lost the deal on one in Ontario, Canada.  Back on the trail again we stumbled across Kathathea a local boat whose owner had just lost her husband and needed to sell her Freeport 41.  Kathathea was pretty worn down with most of her systems not working or in need of repair.  Our original survey gave us a lot to work on and more items came up as we dug through the boat.  Sort of like a can of worms.  We spent $11,000.00 in supplies and gear within the first six months. 

We renamed the boat Big Tuna because, well, she is big and in 2013 she will be palegic like a tuna.  We started out in the engine room figuring that is the heart of the boat in that all of the systems pretty much start from there.  The engine wouldn't start so that was first on our list.  We had to leave the Silver Gate yacht club and make way to our mooring near down town San Diego, but along the way the engine oil cooler end cap parted and allowed salt water to pump into the boat via a 1 1/4inch hose.  We shut down the engine closed the thru hull and tied the skiff to the side of the boat so we could continue our journey. We made it just fine with some help from our friends Joe and Julie. 
So it was obvious that the whole engine cooling system had to be gone through.  We sent the heat exchanger out for service and outright replaced the engine and transmission oil coolers.  I replaced all of the hoses, raw water pump, thermostat housing, freshwater pump, and glow plugs.  We also noted a lot of bad wiring throughout the boat including the engine harness so we replaced that as well.  While we were at it we added a Powerline 120amp alternator and Balmar regulator.

Batteries, inverter, and generator were next in the heart of the boat.  Three 4D AGM batteries for our house bank equaling 600amps keep us pretty well off in the power side of things and for the engine a Optima Group 27 battery.  We regulate the charge between them with an ACR combiner.  The inverter/charger has a remote panel in the salon with a Xantrex Link 20 to keep track of the usage.  At first we were using a Honda 2000eu to supply power to the charger, but then I came across a Fischer Panda 4000AGT generator with 600 hours on it.  This is a 300amp 12 volt generator that has a Kubota base engine.  We have had no problems with it in the 800 hours since installation.

The fuel system had to be addressed next to lift the port restriction with our insurance company.  The previous tank was rotten and then replaced with a holding tank(priority?).  Anyway we split the tanks up into three sections totaling 120 gallons.  After this we replaced the sub floor with 3/4inch marine plywood.

The plumbing was in very poor condition and leaked in many locations.  There was a mix of rigid plumbing and a more standard marine hose throughout the boat.  Plus as an added bonus the stainless water tank leaked at three points.  So out with the bad and in with the new.  We had to take up the flooring forward of the fuel tanks and cut the old 200 gallon water tank out.  We had a new tank built in the Orange County, California area.  The new tank is a little bit smaller 170 gallons. This leaves us room for dive gear and other fun toys.  In reality with a watermaker a person doesn't need 200 gallons.
The rest of the plumbing was all done with the Whale system of rigid pipe and fittings.  We installed a new supply pump, propane instant heater, and charcoal filtration