Ya, Barnacle Bill, it is no longer hidden!! I peeled away all the glass and filler after managing to drop the expanded upper section from the trunk. The bulby (and very heavy) end appears to be cast lead encased in glass. That was fared down to about 1 inch thick for the upper section that led to the trunk. That upper section has a 5/8" thick steel plate or bar running from the lock pin hole and into the center of the lead bulb. I suppose it could have been an I-beam that rusted down to a square bar...but there doesn't appear to be evidence of that in the filler pieces.
My plan is to use the upper section pieces glued together to create a rough 'plug' from which I can make a glass mold in the form of the keel's outer shell. If you can visualize this, I'll lay the cleaned and primed bar/bulb in the mold, fill it with resin & filler and when it sets up, I will shape the edges and fit with the bulb, filling any gaps that remain
. That renewed keel shape will then be glassed before reinstalling on the boat...and we'll have to be mindful of the resulting thickness at the trunk end.
Here is the result of my disassembly and initial clean-up of the bar, leaving most of the filler and glass on the bulb:
https://goo.gl/photos/QBTA8qKTrxTck3kVA
Here is the rough plug from the pieces and you can see where the bar used to be:
https://goo.gl/photos/TxrxJgJiXopbKiBk7
I have added some wood strips here to form the mold's upper edge so we can capture the edge shape. I need to fillet where they are glued to the old glass and I need to decide how to work the area that transitions to the bulb end...too bad I can't simply 3D print a light plastic bulb end to slip into void from the old bar, then bondo things smooth! I guess I could 'sculpt' something in wood with the power grinder!
https://goo.gl/photos/fNTLGMpvjCznPkm39
I thought I had a photo from after grinding and painting the bar with rustproofing paint, but I'll have to go take one!
Anyway, does that sound like a restoration plan?