IMG 1581 After removing the wet plywood, then layering fiberglass mat and roving per Catalina's repair specifications, I then added two 1/2" layers of G-10 board. Used 1/2 blue foam for making templates and then cut the G-10 to match the shape and keelbolt hole positions. I staggered the two layers so the joints between pieces were never in the same location.
093 One of the fiberglass mat layers specified by Catalina. I believe they want 3 alternating layers of mat and roving material, but I recommend a fourth mat layer on top to leave a smoother finish. I also added some 6" wide 23oz 45deg biaxial cloth up the sides of the bilge. Removing two 3/4" plywood layers on our 1984 boat meant that I had to rebuild 1.5" back up. The fiberglass cloth and roving doesn't get all that. Plus, adding two 1/2" layers of G-10 like I did on top of the cloth makes a VERY substantial bearing surface for tightening down the keelbolts onto.
032 Up on 6 x 6's. Note P.O. had upgraded to the 3" heat exchanger, but mounting with a single hose clamp was dodgy. I fabricated a new bracket with strut and bolted it to those extra two holes not used by engine mounts.
IMG 1587 You should add West System Low Density Filler to the epoxy when installing the G10 boards. Press the board into place, the stuff googes up around the sides and fills in the gaps. Trowel or fillet it up neat and let it set. I covered the top layer G-10 pieces with blue tape so I could keep the top finish without blobs on the surface and ready for paint
IMG 1581 After removing the wet plywood, then layering fiberglass mat and roving per Catalina's repair specifications, I then added two 1/2" layers of G-10 board. Used 1/2 blue foam for making templates and then cut the G-10 to match the shape and keelbolt hole positions. I staggered the two layers so the joints between pieces were never in the same location.
014 Home-made gantry with come-along. Adult-size, erector set strut material is available at HD/Lowes. Bolt it up, protect the fiberglass deck and you're ready. The mast needs to taken off to do the compression post support repairs, so using the boom to lift the 325lb motor wasn't an option. After disconnecting wiring, shaft flange, exhaust and engine mounts, it was up on blocks, inside the boat, in 30 minutes. A one person job.
IMG 1230 This rot damage came from water down the mast over time. My 1984 Catalina 30 masthead fitting is open to the sky at the top! Since I had the mast pulled to do this compression post repair, it now has an aluminum plate to cover the opening. Note the hole that the mast wiring came through, in the upper left part of the wood.
IMG 1369 Note bottom two inches of PVC wiring conduit showing some previous water "level" inside the post box. Catalina factory drills a hole down through the post support and into the bilge so the mast wires can continue back to the nav station switches. Rain comes down the wires, and over time, rots the block.
R

IMG 1581 After removing the wet plywood, then layering fiberglass mat and roving per Catalina's repair specifications, I then added two 1/2" layers of G-10 board. Used 1/2 blue foam for making templates and then cut the G-10 to match the shape and keelbolt hole positions. I staggered the two layers so the joints between pieces were never in the same location.

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