Frozen Boom Hardware

[Dave Viglierchio]

I have found a lot of corrosion under the bales on my 1983 vintage C-36 boom. Unfortunately it is as bad as the surveyor suggested, contrary to the seller's thoughts at the time. Does anyone have an opinion on replacing the boom? I'd like to remove the hardware and put it on a new extrusion which is available from Catalina. BUT...I've found most of the screws and fasteners are frozen. Even using an impact type tool the screw heads just round out. Is the next step to grind the heads off and drill or tap and use an "easy-out" for extracting the screw shanks? The bolt on the aft end is frozen too and I don't know what it is attached to inside the boom. Or is there a good reason to buy a whole new boom complete with all fittings? Is there an aftermarket boom available that is either more economical or better performing or both? The boat is used for sailing in SF bay and will do some short coastal cruising soon. Any suggestions would be appreciated greatly. Thanks.

 

[Ron]

Heat-Chisel-(!##@!!#) Words

I just repainted the spars on my Cat 30.There was the same corrosion that you seem to have. Most of the screws would not turn. I applied WD-40 to all of them. Let them soak for a day. Then heated the heads with a torch. I chiseled off the heads on a few to remove the fittings. (the heat is what works) Not too hot but enough to expand and contract the metals. Grind the remaining screw down. And drill out the rest. Acid wash and etch the boom before priming. Work at it before you give up. I almost gave up but it did work for me...

 

[Ricahrd]

yes to heat

You will find that heat is nearly magical at times for getting bolts free...The bolt on the end of the boom? My 1982 catalina 30 has a bolt at the end of the boom to hold the SS bracked for the topping lift, but it does not hold the cap on the boom. The two (or is it 4) pop rivits actually hold the cap on. The bold is just a short one and is attached to the cap. I had to apply heat and lots of pounding to get my boom end off even after drilling out the rivits.I have been trying various things when reinstalling hardware on aluminum. So far the best I have found is using a plastic for sale sign to insulate between large SS hardware and aluminum (boom, mast, mast step, etc). I also use some anti size/anti corrosion compound on all the bolts.I have firmly switched over to the idea of taping the mast and boom and using fine thread machine screws for all my hardware instead of the old concept of freaking sheetmetal screws.Our boats are similar vintage so I certainly understand your problems. Mine has also only been in saltwater.