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Old 26-04-2016, 20:48   #91
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Re: Keel sump repair

Small update.
The grinding is hopefully done on the inside. Every time I say that though we find something. But I'm pretty sure minaret got all the bad stuff.
He cut out the damaged bulkhead and found out that the 1/2" G10 is too skinny. The repair was 1/2" but bulkhead is 3/4". I went out and bought 3/4" G10 for that repair and will use that also for the mast step area backing plate/sump repair. The 1/2" is being used for the aft and middle sump repair. We'll have some left over.

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Just delivered G10!

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Main bulkhead. I saw this and just shook my head.

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Middle sump area almost done. The brackish areas are shattered fiberglass. It amazes me the keel stayed on. Really.

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Mid sump G10 plate.
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Bonded in. Still needs the laminate of course.

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Finally in the construction phase.

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Old 28-04-2016, 21:37   #92
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Re: Keel sump repair

Quick update. Last week was the usual grinding hell. Our friend Bruno at Wauquiez left us some nice treats. I will depict a few here, starting with this sample of the standard of work. Got real tired of seeing this glossy brown gel, totally zero prep, under massive structural laminates. Which then of course had to be ground completely off, 3/4" thick or more in places!



This big chunk of filler which was used to pot one of the aft keel bolt backing plates was buried under a ton of glass in the sump. It popped right out with a chisel after the glass was ground off.
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Old 28-04-2016, 21:45   #93
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Re: Keel sump repair

In these pics the main grind has been completed on the delaminated glass on top of shiny gel around each and every keel sump in the grid liner, for the top 5" or so. Corner grinding is taking place, and you can see I'm using a grinder and chisel to cut off big chunks of delaminated glass in the corners. Very clear evidence. There's yer problem! Loads of corner grinding took time, look how thick that glass is. And it all needed a nice taper ground in after the delam was removed, as well as removing a crapload of bad material.
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Old 28-04-2016, 21:49   #94
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Re: Keel sump repair

More of the same. You can really see how thick the delaminated glass is here. Right on top of shiny gel.
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Old 28-04-2016, 21:51   #95
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Re: Keel sump repair

Ye olde rotten main bulkhead.
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Old 28-04-2016, 21:54   #96
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Re: Keel sump repair

Grinding fun!!


A nice taper ground in to the delam all the way around.
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Old 28-04-2016, 21:58   #97
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Re: Keel sump repair

More horrors, including main bulkhead tabbing on shiny gel.


One side ground off, the other not, so you can see the difference.


Yes, that's one of many bags of itch dust!
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Old 28-04-2016, 22:01   #98
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Re: Keel sump repair

The state of the original laminate in the floor of the keel sump. And fun with G10!!
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Old 28-04-2016, 22:03   #99
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Re: Keel sump repair

More grinding fun on the grid liner ends and around bulkheads and stringers.
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Old 28-04-2016, 22:06   #100
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Re: Keel sump repair

Temporary faux bolts with a release applied to provide perfect alignment of G10 plates when bonding in and ensure enough thread length for nut and washer as well as interior layup-barely.
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Old 28-04-2016, 22:09   #101
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Re: Keel sump repair

Oh yes! Bonding in G10.
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Old 28-04-2016, 22:11   #102
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Re: Keel sump repair

Prepping, patterning, and cutting glass.
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Old 28-04-2016, 22:14   #103
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Re: Keel sump repair

Interior 14 ply laminate in place. Enough for now, hope everyone enjoys, gotta go hang with the kids!
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Old 28-04-2016, 22:28   #104
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Re: Keel sump repair

I was there for some of it and I'm still impressed by the photos.


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Old 28-04-2016, 23:27   #105
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Re: Keel sump repair

Damn! That minaret is an artist!

Thanks again for sharing the pics, guys.

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