I'm looking for some insight into what I should realistically expect from G/flex epoxy and keel movement on an old Hunter 25.
My 1982 Hunter 25 came with a small keel smile. This spring, I ground it out, torqued the keel bolts (132 ft-lb), and slathered some G/flex epoxy in the gap. At haul-out last week I inspected it hanging in the travelift slings and it was still flawless. Survived a lot of sailing, a choppy harbor, and the 10 mile drive to the launch so I was feeling pretty good. But then, after they drove it across the yard and put her up on jack stands, a pair of small cracks formed at the front. I didn't see it happen, but I have 300 lb of batteries in the stern (electric drive) so I'm guessing she probably leaned back a little while resting on the keel, before they got the stands properly tightened.
Is this "normal" or does it suggest excess movement in the keel stub / bolts? Supposedly G/flex can elongate 33%, so I'm worried it may have taken considerable movement to break it. I believe the keel stub itself is solid fiberglass; my understanding is a lot of "smiles" come from wooden core. Anyone else have a smiling hunter to compare? Anyone see G/flex cracking with known-good stub + bolts? I'm trying to gauge how much risk I'm taking if I keep sailing it. I'm guessing (a) I'm overthinking it, and (b) it would be more money than the boat is worth to drop the keel for a full inspection, but looking for a sanity check.
Pictures follow.
Thanks!
Small cracks after haul-out:
Prior to my repair. She had fallen over on the hard which opened the gap; it was barely visible standing up There was what looked like a prior repair with silicone caulk and an outer layer of fiberglass that peeled off easily (you can see the second crack where this "fairing" buckled a bit). No rust stains, so if the keel bolts were corroding they did it stealthily.
After grinding, before cleanup/epoxy. The gap in front looks big, but it's only because I picked out some glass-like old resin that was loose:
Bilge side of the bolts looked fine this spring (for whatever that's worth).
My 1982 Hunter 25 came with a small keel smile. This spring, I ground it out, torqued the keel bolts (132 ft-lb), and slathered some G/flex epoxy in the gap. At haul-out last week I inspected it hanging in the travelift slings and it was still flawless. Survived a lot of sailing, a choppy harbor, and the 10 mile drive to the launch so I was feeling pretty good. But then, after they drove it across the yard and put her up on jack stands, a pair of small cracks formed at the front. I didn't see it happen, but I have 300 lb of batteries in the stern (electric drive) so I'm guessing she probably leaned back a little while resting on the keel, before they got the stands properly tightened.
Is this "normal" or does it suggest excess movement in the keel stub / bolts? Supposedly G/flex can elongate 33%, so I'm worried it may have taken considerable movement to break it. I believe the keel stub itself is solid fiberglass; my understanding is a lot of "smiles" come from wooden core. Anyone else have a smiling hunter to compare? Anyone see G/flex cracking with known-good stub + bolts? I'm trying to gauge how much risk I'm taking if I keep sailing it. I'm guessing (a) I'm overthinking it, and (b) it would be more money than the boat is worth to drop the keel for a full inspection, but looking for a sanity check
Pictures follow.
Thanks!
Small cracks after haul-out:
Prior to my repair. She had fallen over on the hard which opened the gap; it was barely visible standing up There was what looked like a prior repair with silicone caulk and an outer layer of fiberglass that peeled off easily (you can see the second crack where this "fairing" buckled a bit). No rust stains, so if the keel bolts were corroding they did it stealthily.
After grinding, before cleanup/epoxy. The gap in front looks big, but it's only because I picked out some glass-like old resin that was loose:
Bilge side of the bolts looked fine this spring (for whatever that's worth).