Dreaded rusty keel bolts on a fixed keel Catalina 22

[partingclouds]

Has anyone drilled cast iron with a hand drill with the boat in the water? I think it can be done, but would like to hear what kind of cutting oil to use. I plan on using sister bolts
of stainless steel, and would like to be prepared for potential glitches prior to getting my feet wet... just a figure of speech, I hope. Any advice would be greatly appreciated.

 

[Capt jgw]

You don't have the trailer? It would be much easier and a lot less scary to do this on dry land. And I don't think you're going to get very far with a hand drill. Or do you mean a portable power drill?

 

[partingclouds]

Yes, a powered hand drill. Thanks for your advice on the trailer.

 

[CloudDiver]

Get it on the trailer, no questions asked... How rusty are we talking? Pics help.
Powered hand drill in this case should be the 'big one' that has a 1/2" chuck with the extra handle on the side, but most importantly Speed Control! You want to slow the bit speed down to around 600 rpm. For the experienced and skilled this is not a 'hard' job in theory, but it is 'sensitive'. You need to drill out the old bolt shafts dead center to a slightly larger size and re-tap them to the next size up. It's also critical to carefully and thoroughly clean out the metal particles and cutting oil from the holes before setting the new stainless threaded rod. Personally, I would remove the keel from the boat to do this job... but it is completely possible to do it in place.

 

[partingclouds]

Thank you, Cloud Diver!

You are absolutely right about drilling out the old bolts, and now that's the obvious best route to take. It will undoubtedly be easier than drilling new holes in cast iron, given the condition of the bolts, or rather, what's left of them. They're rusty to the point of being unrecognizeable as metal objects...

Having never tried to tap cast iron, I'm wondering how that will go, and would like to know if some miracle adhesive might not be appropriate to place into the tapped holes. After all, the original fasteners were J-hooks imbedded into the casting I believe.

Thanks again, Cloud Diver. I feel confident that I can do this, going slowly and carefully.

 

[CloudDiver]

The big question is if the original J hooks were 304 Stainless or standard steel. Even 304 stainless will rust eventually, but if they are that bad I am guessing they could be plain steel. In the case they are plain steel they will drill out fine... If they are 304 stainless they too will drill out but you need a really sharp drill bit, very slow speed and lots of cutting oil.
Don't fear tapping cast iron, it isn't any more difficult than tapping regular steel... same rules, slow and even drill speed with ample cutting oil.
Its possible to do what you suggested and drill and tap sister bolts in new but adjacent locations. The depth of the 'J' parts of the old ones could be an issue. In any case, I'd still haul out, get her on stands and remove the keel to do this job. I'd be as concerned about the keel to hull joint as I was about replacing the keel bolts. In terms of the keel/hull joint as well as setting the new threaded bolts in tapped holes, Satan's Glue is actually called for here (3M 5500).

 

[partingclouds]

Many thanks, Cloud Diver. I'll proceed with your kind advice, using sharp drill bits, going slowly, using plenty of cutting oil, and a liberal amount of Satan's Glue for peace of mind.

All good!

 

[jibes138]

Don't just use "sharp" drills, you need drills made out of the right material to cut cast iron. Drills made to cut wood even when sharp won't make a dent. Same goes for drilling stainless the right material is critical.

 

[CloudDiver]

This blog is the only source I could find that has good details about Catalina 22 Fin Keel Removal and stud replacement. Interestingly, his work proves that the factory did NOT use 'J' bolts cast into pour, he was able to remove them just by backing them out and found regular studs in threaded holes.
http://svstilltime.blogspot.com/2012/02/keel-bolts.html

I would highly recommend hauling out and removing your keel to do this work... I'm not so sure you can trust the 'drill in place method'.

 

[bffatcat]

This is not a job for a beginner You need the proper tool`s bits ect If you have no experience with this type of job, I would suggest you get someone that does to help you

good luck!

 

[njlarry]

This blog is the only source I could find that has good details about Catalina 22 Fin Keel Removal and stud replacement. Interestingly, his work proves that the factory did NOT use 'J' bolts cast into pour, he was able to remove them just by backing them out and found regular studs in threaded holes.
Keel Bolts

I would highly recommend hauling out and removing your keel to do this work... I'm not so sure you can trust the 'drill in place method'.

Absoulily right. I belive keel bolt torgue specs are for weight of hull on keel not the keel hanging ftom hull. Also should rebed keel with 4200 while you are there.
Please post pics for those who come after you.