Design and Construction
Perry paired a traditional-style deck with a modified fin-and-skeg underbody, a successful formula for cruising boats. Below the waterline, a relatively deep forefoot leads into a powerful fin keel. The generous keel and robust, skeg-hung rudder give the hull quiet authority.
Two keels were offered: a standard 5-foot-9-inch draft and a shoal version that trims six inches from the draft. The hull is solid fiberglass, heavily laid up with layers of 24-ounce roving, 1.5-ounce mat, and polyester resin. The Passport 40 predates the switch to blister-preventing vinylester resins, yet blisters don’t appear to be much of a problem, even on boats that have spent years working in the tropics.
Iron ballast is encapsulated in the keel cavity. Stout transverse floors beneath the teak-and-holly cabin sole and longitudinal stringers provide further reinforcement. The hull-and-deck joint sits on an inward flange, is through-bolted, and incorporates a raised bulwark. Bulkheads and furniture facings are securely fiberglassed to the hull.
Early boats had marine-plywood-cored decks; later boats used Airex foam coring. Most examples carried thick, five-eighths-inch teak side decks set down with abundant Thiokol, although some later models came with molded nonskid. Stanchion bases are mounted vertically for strength. Plenty of exterior teak—including handrails, coachroof eyebrows, and a lovely caprail—dresses the topsides. Deck hatches were initially supplied by Atkins and Hoyle, with Lewmar units appearing later in the production run.
Rig and Handling
A sloop rig was standard. Almost all boats were later fitted with a staysail stay, usually removable. Total working sail area is 771 square feet, and the original design objective was to let the boat be sailed under main alone and easily handled singlehanded.
The primary winches are far enough aft for the helmsman to trim the headsail without leaving the wheel. All other sail controls lead aft through a beefy coaming that makes an ideal base for a dodger. The mainsheet and traveler sit just forward of the coaming, leaving the cockpit clear while retaining good purchase on the boom.
The sail plan keeps the boat moving in light going, but it really thrives as the wind builds and makes little leeway. Easing the traveler usually eliminates weather helm, and the boat is reasonably close-winded for a cruiser. Owners consistently describe the ride as soft and the handling as predictable, swift, and nimble. Fast passages are considered routine.
Cockpit and Deck Gear
The cockpit is particularly well arranged for shorthanded sailing, with the primary winches and sail controls within practical reach. A husky stainless-steel stemhead fitting with a single anchor roller was standard, along with a manual windlass and huge 10-inch mooring cleats.
The standard 36-inch Epson destroyer wheel seems a little undersized. Separate engine controls also require the helmsman to reach through the wheel to operate them.
Accommodations
The interior is simply lovely. The teak joinerwork is exceptional, from solid teak staving on the bulkheads to rounded joints shaped into handholds around the galley and navigation station. All that rich, satin-varnished teak makes the saloon fairly dark, but it also gives the cabin much of its character.
The saloon is arranged around either a U-shaped or L-shaped settee and a lovely table. On some boats, the table is mounted on the galley bulkhead and folds away to create more space. Either saloon settee can serve as a sea berth, and thick four-inch cushions were standard.
About half the fleet came with a head-forward layout followed by a Pullman berth. The other half had a traditional V-berth and a head with a separate shower. The forward cabin offers a forward-facing double berth to port, while every boat has a double quarter cabin aft.
The large galley invariably includes two deep stainless-steel sinks, a well-insulated top-loading icebox or refrigeration, and a propane stove and oven. There are enough bracing points to work in the galley at sea.
Engine and Tankage
The original engine was the old, reliable Perkins 4108 diesel. Boats with U-shaped settees usually retain it because of the clearance beneath the table, while boats with L-shaped settees received later Yanmar engines. Parts for the 4108 remain widely available, and the engine is easy to service, with terrific access from the cockpit.
Under power, 1,800 to 2,000 RPM produces 5 to 6 knots, depending on conditions. A three-bladed propeller was standard.
The original black iron fuel tanks held 105 gallons and were encased in fiberglass to prevent corrosion. That encapsulation can conceal external rust and slow diesel weeping where moisture reaches the welds.
Known Issues
The main material concern is the deck coring. Early boats used marine plywood, while later hulls moved to Airex foam. On most examples, five-eighths-inch teak side decks were laid over those cores with Thiokol. As the adhesive ages, the teak decking can provide a recurring path for water intrusion. Combined with the plywood-cored decks on early boats, this is the principal structural weak point to understand on any particular hull.
The encapsulated black iron fuel tanks are the other notable concern because the fiberglass can hide rust and slow leaks. Otherwise, the polyester-resin hull has an encouragingly clean blister record, even in tropical service. The through-bolted hull-and-deck joint and raised bulwark have also proved durable.
The Verdict
The Passport 40 is a world-class cruising boat, equal parts rugged voyager and elegant yacht. Its sweet-sailing hull and Perry underbody have earned a lasting reputation. Buyers need to understand the age and condition of the deck core and the original tank encapsulation, but the boat offers superb joinery, easy singlehanded capability, and a near-ideal seagoing cockpit.
Pros
- Nimble, easily handled hull that performs well in trade winds and makes little leeway
- Exceptional teak joinerwork and a genuinely lovely, well-planned interior
- Terrific engine access and widely supported Perkins 4108 power
- Clean blister history despite pre-vinylester polyester construction
Cons
- Early plywood-cored decks and teak side decks can admit water as the bedding ages
- Original black iron fuel tanks can rust and weep unseen inside their fiberglass encapsulation
- Standard 36-inch wheel feels undersized, and the engine controls are awkward to reach
