Keel trunk crack

[reefsider]

Figured this was important enough to get its own thread for others easier reference.


As I was restoring my 1987 C22 I found this crack that ended up being larger than it first appeared.

I got the boat with a broken keel cable but this crack appears to be from before this incident as the drill holes imply it was poorly fixed the first time. I don't think it would be a good idea to ignore this at this point.

You can also see "bruising" where there is delamination internally from impact.

Here are some pictures:

I have done a great deal of work on the boat to this point but am running out of time with my work space and am not sure I am capable of this big a job. There is a wood bulkhead for the sink area in front of the keel pocket so access would need to be cut for a proper repair being as it's on a corner and a fairly high stress area.


Advice and help would be much appreciated. Also see my other post here:
https://forums.sailboatowners.com/index.php?threads/help-did-i-make-a-huge-mistake.178987/

 

[ilance]

Reef:

I guesss I'll weigh in on the "Pollyanna" side.....

You've got a lot of work into your boat now. I would consider that place to be relatively low stress, until a keel whacks it.

My father used to say anything Fiberglas was fixable. I think, in the era of modern composites, that's even more true than ever! If you take a stab at sealing up that crack, and it fails......try again! With the knowledge you e gained, you can only do better.

I'm coming at it from a similar angle. I got a "free" Catalina 22 and trailer (no motor). Will it be free? HECK no! Will I be sailing when I want to? Nope. My season is already on......and I haven't even started to put things together with glue!

But: like the others here, I'm having a bit of fun with the process. Do I wish that I'd held out for a more complete package? Sometimes......I'm sure that'll get worse if I miss my season! Still....Wayward Star is mine......and will only be all the more so when I've completed her projects. There's value to me in "saving" her.......andnits not just a financial call.

 

[Gene Neill]

Grind out the entire crack, and fill the void with West Systems epoxy, thickened with West 404 filler.

Easy peasy. I'd invest in a respirator and a disposable suit for the grinding is all. Or maybe @ilance can loan you his.

 

[ilance]

Ouch! (But totally true!). Me and Admiral have come to a reasonable understanding about expectations for fiberglass work.......not exactly my preference, but compromise is HEALTHY when dealing with that rank!

Because in the end, they can just order it to happen anyway! ‍

 

[pclarksurf]

+1 for @Gene Neill -- Open it up and fill with epoxy. It really doesn't look that bad.

 

[reefsider]

Thanks for the advice, I have ended up cutting out the floor to access the inside. I installed the old bulkheads and locker fronts first for support. When I did I found the mast support extremely soft and wet. I'm not sure how important this is because it's not very big and not very bonded to the hull. Also the keel pocket support in the area under the sink is worse than I thought and needs to be replaced.

However, seeing this, I mentioned it to a friend and he came over with a moisture meter. We found that there is a lot of moisture in the port side of the deck as well as the mast step and mast support. The readings on the post side being the highest, in some places reaching 15 or just above on the meter. The moisture is also that high until about halfway up the support for the mast.

Should I be replacing the mast support? What is the best way to do this?

I have the technical manual and have seen the modifications for distributing the load from the mast. Would this be a good enough fix for the deck as long as I removed all the fittings and reseal everything?

So now I have to consider my options. I will lose my work space in a month and a half so it would be best if I could get the keel back on with the boat interprotected and painted with AF. if the boat is able to float I have somewhere I can finish most of the rest. If not I will have to pay for storage as I can't work on the boat at its new home.

Now I am wondering if it's worth it for a boat that has a lot of moisture in the deck and other structurally important areas? Would I be better off to stop the work and part it out so I can go out with more knowledge and a moisture meter and find something that will last a bit longer? My friend said that's why he doesn't buy boats that have been left neglected/abandoned for many years; They are often rotten or rotting.

 

[ilance]

"Mast support".....as in the compression post, the teak one, visible in the center of the cabin, or the wood block between the liner and the hull?

Neither should really be that big a deal. The compression post is on eBay for around $20, needing varnish. The blocking can just be epoxy saturated wood. Bust it out, epoxy it's replacement, and tab it back in.

I've stumbled on a couple little things between the liner and the hull that caught my epoxying attention......no biggie. Get to it, man! You're way ahead of me......and have already done so much! For heavens sake: stop mining into things so hard and start assembling. Honest: this site can awaken the perfectionist in all of us.....but, you're dealing with a 30 year old, cheaply made, plastic boat. Use good epoxy technique and you're already making something better than it was originally!

I keep finding distractions on mine too.....and keep having to remind myself of the same......there's just no reason to get "Swan-level" perfection into your boat. Unless your primary love is fixing and perfecting, and not sailing.

Just my opinion, FWIW. (Usually not much)

 

[reefsider]

Thanks ilance, the mast support pole in my boat is a stainless pole, it's the "New Design" hull. It is the wood in the liner between the pile and the keel pocket and there is a tab that goes down to the bottom of the hull. It doesn't look like it would be the easiest job to cut out and glass back in but doable. It's a pretty confined space in my boat (not sure what the original design is like).

The mast support isn't really my biggest concern, although it's just more work that needs to be done and the list keeps getting longer. I'm more worried about the moisture in the rest of the boat especially the deck where the chain plates and mast supports are. I just don't want to do a ton more work on a boat that is already questionable. At this point the trailer and keel have been completely redone with new everything so that's worth something and the other parts are worth a bit too.


I wanted to redo the keel pocket cracks for safety. I know to keep the lift mechanism looked after; That being said things happen and if the winch were to fail it could be a serious problem if not fixed properly. Same with the mast support and deck fittings. These are things I would rather not take chances with.

If the deck can be properly supported then I can work on that but I don't want to have to start cutting apart the deck to fix soft spots.

At this point I'm ready to chop the hull up and scrap it so I don't really care what it looks like it's more about the amount of work and time it will take to get it back to where I can put it in the water with or without the mast.

 

[rpludwig]

you already have a ton of sweat equity and some dollars invested, a good keel now and lots of positives...most of us have been in the "give it up" mindset from time to time...I'd evaluate what's down the road, sails, standing/running rigging and other must do items...soft deck spots can be dealt with if not extensive, likewise on the mast support....chin up!!! my 2 cents....

 

[ilance]

Agreed. Plus: I'd weigh the, "what's the NEXT boat gonna need?"

There's always something to get after. The boiled down question is whether you'd just end up doing more on the next boat. My own "free" Mk1 bums me out with the list I keep adding to......but, I've had to accept that much of that is my own doing......I keep finding things.

I keep straight by believing that I'm doing these things for joy, and the pride of work well done. Seriously: my original boat was shoddier than it is now, when new! "Good enough" is honestly a hard calculation......but an extremely valuable one. My crappy OEM plywood has been made stronger than it ever was, by the use of modern goop.......and it's actually sealed now! My decks are gonna be stronger and shinier than new.......it's gonna cost me $500-$700.......and my summer sailing........but, I'd probably be here with any boat. When done, Wayward Star will be "mine" in a way that is more valuable than the cash outlay, or time calculation.

How soft are the decks? Get harsh with the guesstimate of what you need yet to do.......but, I see only a day of grinding and epoxying there.......less if you're dedicated or skilled.