Most of the Cal line uses a galvanized I-beam to resolve the forces of the mast
. This beam runs across the boat, the fiberglass step in the cabin sole
is wrapped around the sides and top of it. In the Cal groups it has been argued back and forth whether the original plans called for stainless.
Clean it up and see how bad it really is before committing to immediate replacement. I haven't done this job, but there are pictures and help out there to do the job. The mast
post sits on the center of the I-beam. The shrouds are connected to the beam using the main bulkhead, chainplates near the top of the bulkhead, the tabs on the beam near the bottom. The Cal 40 also has 1/2" steel rods to tie the chainplates to another set of tabs on the beam. One of the previous owners of my boat installed 4" deck ports
in the sides of the fiberglass step to monitor
the condition of the beam. A group of Cal owners were passing around a commercial
version of an endoscope (camera on a flexible controllable stalk) to inspect their beams. There is also a Cal 40 owner here in the PNW that has done this job.
I don't remember all the details, but at the very least some disassembly of the cabin
in front of the main bulkhead is required to cut the top and/or side of the fiberglass step out. Then the beam can be slid out. I believe that at least there are drawings if not even people working on group deals of beam manufacture.
You need to sign up on the Yahoo group Cal_boats to see the pictures in the first link below, and to participate in the email
list. These guys are a good knowledgeable group of Cal owners.
Pictures of Mariposa, a Cal 29
replacing the beam. He was also redoing the cabin
, you don't need to gut the whole boat as he has done.
Here's someone I know that had to replace the main bulkhead, still can't see the beam except for the tab on top.
Jedediah Smith : photos : Main Bulkhead Replacement- powered by SmugMug