Keel/hull joint - the Surprise!:
A I kept grinding away at to expose the keel joint I reached a point about three feet in front of the rear of the keel where the joint was covered in fairing compound (or whatever they used as fairing compound
). Kept grinding and it kept getting thicker so I took a step back and did some thinking as to what was going on. While I was staring at the keel it became apparent that this was a rather large area covered with fairing compound (Hmmmm!) and quite a few spots that - after a hit with the grinder - looked like this:
This was visible through the remaining primer and areas like this were spongy to the touch. Obviously applied badly. I kept grinding away at the filler and - finally - got to the keel! All around this spot the filler was not well adhered and I could chip it off easily with a screwdriver. Double Hmmmm. The filler was really thick and most areas showed cracking that usually is indicative of a too-thick application of filler that has shrunk. I kept chipping away and here's a progress shot:
It chipped off really easily - too easily
. I worked on it until I hit metal - only it was metal in an area I was not expecting! Triple Hmmmmm! Ok, gotta see what's under all this! Here's a shot of the filled area on the other side:
Total area just under 3 feet by 2 feet. Intrigued, mystified, a little horrified, I kept chipping away. Finally I got to this:
This is a 1/2" thick shaped plate (both sides) thru-bolted through the stub and welded to each other and the rear of the keel! What the he** is this? I know it didn't come from the factory this way - that's obvious when you see this:
That's an area that was covered with filler that had been applied over bottom paint! Which explains the rust under the filler
. The total area of filler was needed to fully cover the thickness of the plate, and in areas the filler was close to if not over an inch thick. So...
a: I can't un-chip the removed filler so - gotta repair it
b: I would not tolerate this type of sloppy work on my boat so it will be fixed correctly!
c: I already have a plan!
What me and the guys here can't figure out is what this repair was for! There's no evidence of hull damage due to a grounding (believe me, we looked inside and out, and based on the quality of the filler job any underlying repair would have been noticeable). The keel itself is solid - and the bolts were at proper torque specs. There's no other repair areas on the keel. There's no apparent keel damage unless it's under the plates - and I can see the rear of the keel between the plates from behind. It looked like the plates were formed, shaped and installed very well which leads me to think that whatever happened a naval engineer might have been consulted. As usual it was the final steps in the repair that turned to
.
The silver lining? Based on what I'm looking at, the repair makes the keel stronger than factory. I'm less worried about running over a submarine now!
Stay tuned for the repair plan.
Cheers,
Mark