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Catalina 30 Bilge Repair |
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Jack Gray |
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The reason for the original repair is to fix a design and manufacturing deficiency that is common to Catalina and other boats made before 1994. The use of plywood and later white oak beams as a structural spacer between the layers of the hulls keel base and bilge was a good practice in concept. However, usually inadequate steps were taken to encapsulate the wood to prevent the intrusion of water. The thin layer of only gel coat on top of the beam was particularly a problem. Fiber glass over the beam to add strength to the system was really needed and better sealing of the keel stud holes was usually not done. The problem is only exacerbated in our area of the Great Lakes because most owners dry dock their boats during the winter subjecting the system to thermo cycles. |
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The problem symptoms are seen at the joint between the keel and hull when the boat is in dry dock. Water weeps out of cracks causing a weakness in the outer surface structure. Pieces of surface material can be loose and fall out. The condition is demonstrating a water path from the bilge. The boat owner seeing the Catalina smile, typically tightens the keel hex nuts. This helps temporally, however, since the spacer is wet wood, it will compress a lot more. This cracks open the top layer of gel coat and fiberglass in the bilge even more allowing water to soak the spacer. In advanced cases, spider cracks form around the hull and keel joint along their entire exterior surface. Eventually as the wood rots, the keel can fail or a least shift in certain circumstances. This will undoubtedly occur at the wrong time. So for a few hundred dollars and a little labor, the problem can be fixed avoiding a future difficult repair. |
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The Repair |
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The first step is to remove the top layer of gel coat and fiberglass. This can be best accomplished using a high speed Dremel cutting disc. Cut a perimeter just prior the curve of the side wall at the base of the bilge and remove the top layer of material in sections. It will easily delaminate with a wood chisel. Next use a 2 inch Forstner bit to remover the oak spacer. You can get very close to the hull fiber glass and remove the rest with a wood chisel. Use several size chisels to remove the rest of the wood. You may have to get a little creative in the hard to get places with a combination to drills and Dremel cutters. Think of it as an act of love. |
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I have decided to put back a 7/8 " thick White Oak spacer plus a triple thickness of mat and Roving below and above the spacer. I will be using Epoxy instead to polyester. It is stronger and more moisture resistant. I plan on using a filler to make a peanut butter consistency slurry to fill voids and the perimeter of the white oak spacer. |
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Also "over drill" the holes around the keel studs. The entire structure will be about 1 3/8 inches thick. This is in comparison to the original 1 1/2 inch spacer and 1/8 thick fiberglass and gel coat. The spacer will be entirely encapsulated with epoxy. |
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I plan on doing the repair in two steps for the epoxy work. It is very important to wrap the studs with a Teflon tape before the job is started. This allows the keel studs to be tightened when the job is complete. The next step is to first lay down the fiber glass mat and roving combination. That’s the way it is sold up here these days. I will also set the spacer and fill in the perimeter and holes around the studs. After a one day cure I will wipe down the epoxy with water and then sand it a little and vacuum it up. |
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Cruising Corner |
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Gayle & Eric Locke - Cruise Committee |
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Spring is just around the corner and it’s time to start making your reservations for the CRCA warm, summer cruises. Use the enclosed 2004 Cruise Reservation Form to secure your spot. |
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To fill out the form, just check off cruises you want to attend and send the form to us along with your deposit checks -- |
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a separate check for each cruise. |
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The checks are a deposit only. When you get to the marinas, you sign in and pay them. Your deposit check will then be returned to you. If you don’t show, the check will be cashed, because marinas charge the club for the reservation. The exception is Metro Beach – those checks are cashed right away, because the club has already paid for the reservations. Contact us if you have questions. |
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The following cruises and events are scheduled: |
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May 15, 2004 Fun Race and Picnic |
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Saturday, June 5, 2004 |
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Cruise Leaders – Bousums 586 954-2727 |
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Morells 586 186-1673 |
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Saturday, June 19, 2004 |
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Cruise Leaders – Kurkowskis 586 675-8211 |
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Lauricellas 586 948-3631 |
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Saturday, July 3 and Sunday, July 4, 2004 |
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Cruise Leaders – Posts 586 412-7864 |
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Saturday, July 10, 2004 |
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Cruise Leaders – Creeds 248 623-0628 |
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Lundys 586 228-5864 |
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Wings 248 373-5463 |
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Saturday, August 7, 2004 |
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Cruise Leaders – Smith’s 248 553-3162 |
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Saturday, August 7, 2004 |
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Cruise Leaders – Gayle & Eric Locke 248 526-9686 |
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Saturday & Sunday, September 4 & 5, 2004 |
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Cruise Leader – Joe Jenosky 244 299-2396 |
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Saturday, Sep 11, 2004 |
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Additional details for all events will be provided later. |
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Gayle and Eric Locke, “Knight‘n Gayle” |
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Continued on page 4 |