Lead Keel Boat Replacement

[Chasing Summer]

Hi all ... I've search the forum and can't find what I'm looking for so I'll post a question. I'm located on the US west coast.

Please: no suggestions on how to do it myself, drill all the way through and use all-thread, or simply screw in long lag screws.

I need to replace all nine 1" boats in an 8000 lb lead keel. Maybe some one out there has had similar work done and was happy with the company that did the work.

Thanks, in advance, for everyone's input.

[Chasing Summer]

Well, today I removed the nut from another keel bolt. Again, it came right off in my hand. This time it was corroded a little farther down. It was suggested that it was galvanic corrosion, but this break was below the bronze backing plate.
So, that's 2 of the 9 bolts corroded off. What do you suppose the other 7 look llike.
I called Mars Keel ... they could do a great repair but I can't afford the shipping across country.
I emailed Duro Keel ... again, shipping ... they're located near Mexico City. Also, very expensive.
Called a local guy but I guess he's to busy to talk to me. He said he's call back, which he, of course, didn't.
So here's the plan: raise the boat or take the boat off the keel and set it on stands beside. Core around all the bolts and dig out the lead. Cut off the bolt down inside and thread on long coupler nuts with new all thread ends. Lots of Loctite. Re-pour are cored out cavities. Set the boat back on the keel.
:-)
So, whadda yawl think???

[neilpride]

Its 7000 pounds the ballast right? check if the mast step rest in the keel if you plan to drop the keel, anyway, drop the keel , melt the lead , pull off the old crap and install new fresh SS bolts, lots of 5200 and a good travelift operator do the trick... i guess....

[Chasing Summer]

Deck stepped mast. Stepped on re-inforced deck, double ply interior bulkheads, fiberglass tank dividers ... all just fwd of the fwd keel bolt.
Private yard, no travellift :-( ... hydralic jacks, pads under the stands, good crane operator.
Have people done what I'm contemplating? coring around the old bolts and using couplers? I have no idea how long the originals are or even if they are all-thread with washers or J-bolts.

[minaret]

IF you can find a good local foundry, you may be able to get a new keel made from the old. You probably have J bolts. What you do is get new rod for bolts, put it all in the hull holes after pulling the keel, and weld on a plate to hold the "bolts" in alignment. Then have the foundry use your keel as a plug to make a "flask" for the new keel, melt the old one, and use it to pour the new one with the plate held in the correct place by a jig. Simplification, obviously. If you can find the right foundry, it MIGHT be much cheaper than shipping it for repair.



I know you said don't mention it, but sistering lag bolts is quite common. Mars has quite a bit of info on it, I believe. It's comparatively easy and cheap.

[Chasing Summer]

that would be the ideal way to go ... but finding a foundry and one big enough is the problem.
Maybe I could just melt it on the stove in my motorhome :-) Pour the new on right in place.

[onestepcsy37]

saw a picture on this mars keel web page showing a worker using intense heat to melt a channel alongside the bolt. then he apparently removes the bolt, inserts a new one, and probably puts some new lead back in the channel.

Keel Bolt Replacement | MarsKeel

with the right equipment it might be possible for a determined amateur to do likewise.

[Chasing Summer]

ya, I talked with Mars Keel and they told me about that. ... and to think a couple months ago I sold my big acetylene tank and both my torches. Nine bolts, though, that's a lot of chanels. I am determined ... not sure how much yet. I suppose technically I could do it ... but ... sigh

[Terra Nova]

Originally Posted by Chasing Summer

Well, today I removed the nut from another keel bolt. Again, it came right off in my hand...
So here's the plan: raise the boat or take the boat off the keel and set it on stands beside. Core around all the bolts and dig out the lead. Cut off the bolt down inside and thread on long coupler nuts with new all thread ends. Lots of Loctite. Re-pour are cored out cavities. Set the boat back on the keel.
:-)
So, whadda yawl think???

I think you make it sound a lot easier than it will wind up being. And inevitably this will create a future problem with deadly serious potential--buried keel attachments that cannot even be inspected, the service of which requires keel removal.

[Chasing Summer]

Most things explain very much easier than they really are.
One of the reasons I'm throwing this all out here is to get your very opinion. See, you've brought up something I hadn't thought about before.
I really think the solution is a new pour, but where and how, and by whom. I can't afford either Mars keel or Duro Keel. I also don't want to die from lead fume poisoning. The only thing I know for sure is that the keel has to come off.

[DeepFrz]

Just for the edification of our members how much was the estimate provided by Mars Keel including shipping both ways?

[Terra Nova]

Originally Posted by Chasing Summer

...The only thing I know for sure is that the keel has to come off.

Not necessarily.

It is possible, on some installations, to install new (sister) keel bolts, in place.

[Chasing Summer]

Originally Posted by DeepFrz

Just for the edification of our members how much was the estimate provided by Mars Keel including shipping both ways?

Email from them MarsKeel last year:
As mentioned it would be based on the keel pick up from your yard Sothern California, brought back here all keel bolts replaced with 316 grade Stainless steel ones, keel inspected, refurbished, brought down to bare metal, faired with west system epoxy , epoxy painted returned ready to install @ estimated cost of $ 7000.00 USD not exceed $8 ,000.00 USD all inclusive.

The quote from Duro Keel was worse yet. Quoted from the email.
Unfortunately in your case you would have to dismount the keel and I would pick it up, take it to the factory and implant these new bolts.
Than take it back to San Diego and remount.
The transport cost including custom brokers and customs for both movements $8,400.00
The repair cost, including 8 s.s. type 316 bolts and nuts $3,200.00 That would be the best solution. Total $11,600.00 plus the cost of taking off and remounting the keel.
Making a new keel 9000 lbs with one transport $28,600.00, credit for the old keel $5,400.00

[DeepFrz]

Thanks for that. The $8,000.00 doesn't sound to bad at all but over 10,000 including removal and installation i would suppose. Probably budget $12,000. to be on the safe side.

[Chasing Summer]

Terra Nova ... due to the arrangement of the main bulkhead and bilge tank sistering the keel bolts would be a tremendous amount of work. Yes, that was one of the options but I abandon it early on.