Prop Shaft Log clearance HELP!

[chrisings]

Hello Forum Folk,
I am installing a new propeller shaft and PYI dripless on our ’83 Catalina 30. I will start a different thread, with photos, to share the success of the day, replacing the cutlass (Cutless©) bearing.
This thread, unfortunately for me, is to ask for some input from the collective wisdom of the Catalina Owners forum.
When attempting to slide the dripless bellows on the prop shaft log I discovered that there is insufficient clearance between the log and the hull. I’m not sure how better to describe the issue and can’t take a photo due to the tight fit. Basically the bottom of the log is too close to the hull.
One of the reasons I wanted to replace the old stuffing box was because the old shaft log hose didn’t look like it was very securely clamped to the log. Now I know why.
Has anyone seen this before?
Thanks!!!

 

[Donnybrook]

Yes. My C27 had the same issue. I used a Dremel with a small cutting bit. Then emery cloth on a popsicle stick. The hull seemed pretty thick in that area, so I don't think you need to worry about taking out too much material. A pain, but it can be done.

 

[chrisings]

Yes. My C27 had the same issue. I used a Dremel with a small cutting bit. Then emery cloth on a popsicle stick. The hull seemed pretty thick in that area, so I don't think you need to worry about taking out too much material. A pain, but it can be done.

Thanks, I was thinking that was one solution. Just wasn't sure how thick the glass is there. Sure would hate to have a 1/8" thick hull

 

[Elysium_Van_Isl]

When I installed mine last year I had the same problem. I totally didn't expect it either, so with the machinist standing there ready to fit and face the the shaft coupler I started to get a little red in the face. Not only did I look silly, but I could see those dollar signs ticking by...
I sent him away to tackle another of his jobs, and puzzled it out on my own.
For me, the PSS would neither slide on far enough because of the clearance under the log, nor could it tighten properly because the log had so much taper that it slid downward.
I cleared out some of the fiberglass under the log to make JUST enough room for a full slide-on fit using curved chisels, sandpaper and a dremel.
So far so good!
Remember to put a hose clamp on your shaft once it's installed to keep everything secure.

 

[chrisings]

When I installed mine last year I had the same problem. I totally didn't expect it either, so with the machinist standing there ready to fit and face the the shaft coupler I started to get a little red in the face. Not only did I look silly, but I could see those dollar signs ticking by...
I sent him away to tackle another of his jobs, and puzzled it out on my own.
For me, the PSS would neither slide on far enough because of the clearance under the log, nor could it tighten properly because the log had so much taper that it slid downward.
I cleared out some of the fiberglass under the log to make JUST enough room for a full slide-on fit using curved chisels, sandpaper and a dremel.
So far so good!
Remember to put a hose clamp on your shaft once it's installed to keep everything secure.

Thanks, yeah I was totally surprised too. I had the new shaft all set to go, living 3 hours away from the boat I've learned to try and plan for every unexpected bump in the road and bring all the extra tools possible. The Dremel was, unfortunately, not something I even considered. The good news is that everything else went smoother than expected so this weekend I just need to head up with assorted tools of fiberglass destruction

Well at least I think that's all I need to do.