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**HappyMdRSailor** · 06-11-2015, 05:14

Quote:

Originally Posted by NahanniV

Ok, I'll bite. Where did you get that picture from? Looks worse than mine. Did they fix it ? How ?

Cheers,
JM.

Oh it's definitely mine JM...

20 ton boat was bouncing (read pounding) on it's keel for a very long time...

This web crack actually wasn't too bad to repair at all... The aft end joint at the hull showed no signs of flexing or damage...

Ground down to nearly zero material at the crack, taper 12:1 out... layup there 1708 about 1" thick overall, and additionally tapered about 1/2" either side back up to the hull interface 1' either side... More than 1 yard of glass, but it wasn't 2...

Big hunk o hangin' lead... 9'x2'x2' overall... 8 ton...

NahanniV · 01-05-2016, 06:23

I have just finished the majority of this repair.

It was funny that the day I completed it I saw a post by minaret saying that stitch-mat was probably not the best for achieving a good fibre/resin ratio (oh well, too late now). http://www.cruisersforum.com/forums/...ml#post2109908

15 layers of 1708 on the inside. I put the four smallest layers on first, working from smallest up, then put the rest on from largest to smallest.

I applied each layer separately, resin first then worked the resin through the cloth and out to the edges before applying the next layer. There was not much excess, just coming through the cloth and a bit at the edges; I'm not sure if it was resin rich, but I don't think so. The roller did not work well, too sticky and moved the cloth. I mostly used plastic "Bondo" scrapers to smooth the cloth and work the resin through. I did get all the air out, it was a sunny day and I could see light from outside through the layers.

NahanniV · 01-05-2016, 06:50

Next I added a small bulkhead just forward of the fuel tank.
Not sure if this was necessary, or how much good it will do, but it will keep things stored in the compartment from getting lost under the fuel tank.

I used 1/2" fir plywood (I had it). Cut it with a 1/2" gap to the hull. Sanded away the gel coat on the floor pan with 40Grit on a random orbital. Sanded the edges of the plywood where the tabbing would go. Sealed the edges with several coats of epoxy. Attached the plywood to the floor joist. Then tabbed it in with three layers of 1708 with a 1" radius. I will finish coating the plywood before painting it.

**minaret** · 01-05-2016, 06:55

Quote:

Originally Posted by NahanniV

I have just finished the majority of this repair.

It was funny that the day I completed it I saw a post by minaret saying that stitch-mat was probably not the best for achieving a good fibre/resin ratio (oh well, too late now). http://www.cruisersforum.com/forums/...ml#post2109908

15 layers of 1708 on the inside. I put the four smallest layers on first, working from smallest up, then put the rest on from largest to smallest.

I applied each layer separately, resin first then worked the resin through the cloth and out to the edges before applying the next layer. There was not much excess, just coming through the cloth and a bit at the edges; I'm not sure if it was resin rich, but I don't think so. The roller did not work well, too sticky and moved the cloth. I mostly used plastic "Bondo" scrapers to smooth the cloth and work the resin through. I did get all the air out, it was a sunny day and I could see light from outside through the layers.

Sounds like you laid it up carefully, should be just fine. If it's a little rich it really won't matter much in a repair that size.

**minaret** · 01-05-2016, 06:56

Quote:

Originally Posted by NahanniV

Next I added a small bulkhead just forward of the fuel tank.
Not sure if this was necessary, or how much good it will do, but it will keep things stored in the compartment from getting lost under the fuel tank.

I used 1/2" fir plywood (I had it). Cut it with a 1/2" gap to the hull. Sanded away the gel coat on the floor pan with 40Grit on a random orbital. Sanded the edges of the plywood where the tabbing would go. Sealed the edges with several coats of epoxy. Attached the plywood to the floor joist. Then tabbed it in with three layers of 1708 with a 1" radius. I will finish coating the plywood before painting it.

Looks good, should be an overkill repair for this. Where was I for this thread?

Sorry man!

NahanniV · 01-05-2016, 07:13

Last, I did the outside.
Had a hard time figuring out how to pattern the complex curves; Ended up making a pattern for each side and combining them.
8 layers of 1708.
Largest patch to smallest.
Same technique as inside, but added a bit of structural filler to the epoxy because I was working overhead.
After the last layer I mixed up some epoxy and structural filler and spread it over the patch then covered it with 6mil polyethylene an smoothed it out.

I will likely need a bit more filler.

Once it has cured I plan to do a post cure using some heat lamps inside and out.

I'm planning to have the boat lifted to paint the bottom of the keel a week before my launch, so that will be a bit of a test.

Thanks to everyone who offered suggestions; Obviously I could not use them all.

Cheers,
JM.

**HappyMdRSailor** · 03-05-2016, 05:13

Quote:

Originally Posted by HappyMdRSailor

What a fantastically well documented failure ! I think you're on the right track with the 1708, epoxy, and lots more grinding...

The above quote was included because you really can get creative with the outside profile of the keel root changing to accommodate whatever layup That would make everybody confidently happy! Me??? I'd be 1/2" over what was there before, but I'm a worrier...

Honestly.... with this much work, and this major importance I would get our resident genius minaret involved... If there's ever been a repair on a boat... He's done it... more than once!

I'll send him a PM with the link here for you...

Quote:

Originally Posted by minaret

Looks good, should be an overkill repair for this. Where was I for this thread?

Sorry man!

I have NO IDEA .... Prolly screwing around... with that insane deck repair that I would have dragged to the dump... Being that it woulda taken me more years than I have left...

Absolutely stellar job JM... BRAVO on our "non professional" jobs looking "every bit the business" to handle what's thrown at it!

troppo · 06-05-2016, 00:47

JM, I enjoyed following your 'adventure' with that serious repair job. I reckon you did a great job and I have learned a thing or two seeing what you were doing.

Have fun out on the water.

troppo