I've scanned the archive section of the site with regard to "Bulkhead replacement" for the Catalina 27 and wondered how some of the folks who were soliciting feedback on this task made out. I have to replace both Bulkheads in order to sail Stargazer again (safely). Obviously, with the mast in place now, I'll have to wait until its hauled and tackle it in the Spring. I'm not a carpenter by any means, but I can follow directions. Considering the criticality of the bulkheads, I just want to make sure that this is a task that I can accomplish correctly. It seems too simple, but taking out the old bulkheads, and using them as a template and cutting new ones - just seems too easy. But perhaps its so... I'm looking to dialogue with someone who has actually done this before and get some pointers on how best to tackle it. Another thought is that if I can do this right, I could digital photograph the process, and capture it on a webpage so that others could learn from it. A few questions that come to mind as I begin to plan the project: Do I need a jack to hold up the upper deck when the starboard side bulkhead is removed? What sealant is best for sealing the bulkhead back in place? Must I remove all of the cabinent section on the port side to pull the bulkhead or can I work around the cabinent? I also would welcome a fellow Cat 27 owner who might live in the CT shoreline area and take a look and give me their thoughts. Thanks in advance.
Bulkhead Replacement
- Thread starter Christian7591
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Peter
Christian, the bulkhead replacement is really easy. We replaced ours, one at a time, with the mast up and the boat in the water. Make sure you use only 1/2 inch ply (and most would recommend marine ply). Any thicker and it won't fit..don't ask. Recommend that after you cut the ply that you seal the ply edges with epoxy to keep water from getting in again. "Do I need a jack to hold up the upper deck when the starboard side bulkhead is removed?" We didn't. "What sealant is best for sealing the bulkhead back in place?" We didn't use any, and the original had none. "Must I remove all of the cabinent section on the port side to pull the bulkhead or can I work around the cabinent?" We easily worked around it. Peter
Bulkheads
Christian, I replaced both bulkheads in my 78 C-27 in a weekend. It really is that easy, as long as you can get the bulkheads out in one piece (e.g. not too rotted). Alternatively you can make a template out of cardboard construction paper as a backup. I didn't brace the deck and the new bulkeads fit in nicely. As Peter said, seal the ends of the new bulkeads with a clear expoy sealant (from West Marine or Jamestown distributors) and make sure the old chainplates are servicable and well caulked with an appropriate sealant, I believe I used 3m 4200 but DON'T USE 5200 you will never be able to remove it. This should protect the new bulkheads from rot. My boat is in the Boston area so I'm closeby if you have any other questions. -Matt
Christian, I replaced both bulkheads in my 78 C-27 in a weekend. It really is that easy, as long as you can get the bulkheads out in one piece (e.g. not too rotted). Alternatively you can make a template out of cardboard construction paper as a backup. I didn't brace the deck and the new bulkeads fit in nicely. As Peter said, seal the ends of the new bulkeads with a clear expoy sealant (from West Marine or Jamestown distributors) and make sure the old chainplates are servicable and well caulked with an appropriate sealant, I believe I used 3m 4200 but DON'T USE 5200 you will never be able to remove it. This should protect the new bulkheads from rot. My boat is in the Boston area so I'm closeby if you have any other questions. -Matt
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Dave
Bulkhead
Christian: I too, have replaced my bulkheads....nothing to it. Just undo the chainplates an a few screws holding it in place. I used 1/2 in marine plywood. I took the bulkhead to a local cabinet maker and let him do the cutting. I also let him put on new formica on the outside to give it a true professional look. I used nice bright white formica which lightened up the whole inside of the boat. Putting things back was no problem. A few holes drilled for the chainplates and a few other screws as I remember. Did not need to shore up the inside (never even thought about it) and all went well. I sail with a lot more assurance knowing that my mainstays are not going to come ripping out....Good luck...DAVE
Christian: I too, have replaced my bulkheads....nothing to it. Just undo the chainplates an a few screws holding it in place. I used 1/2 in marine plywood. I took the bulkhead to a local cabinet maker and let him do the cutting. I also let him put on new formica on the outside to give it a true professional look. I used nice bright white formica which lightened up the whole inside of the boat. Putting things back was no problem. A few holes drilled for the chainplates and a few other screws as I remember. Did not need to shore up the inside (never even thought about it) and all went well. I sail with a lot more assurance knowing that my mainstays are not going to come ripping out....Good luck...DAVE
Thanks for response
Thanks for the reassurance and guidance on this. Sounds like something that I can handle. Just need to get the supplies and the proper tool for cutting the marine plywood. The formica idea is great as well.
Thanks for the reassurance and guidance on this. Sounds like something that I can handle. Just need to get the supplies and the proper tool for cutting the marine plywood. The formica idea is great as well.
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Peter
Cutting ply
We simply used a jig saw to cut the ply, and it was easy (albeit a little stressful) as we didn't want to make big mistake and have to get more ply. Peter
We simply used a jig saw to cut the ply, and it was easy (albeit a little stressful) as we didn't want to make big mistake and have to get more ply. Peter
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Matt
Plywood
We used a jigsaw to do the cutting as well. If you are looking for a good source Boulter Plywood in Somerville Mass was great to deal with. Good Luck, Matt
We used a jigsaw to do the cutting as well. If you are looking for a good source Boulter Plywood in Somerville Mass was great to deal with. Good Luck, Matt
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