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02-02-2017, 21:57
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#31
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Resin Head
Join Date: Aug 2007
Location: Seattle WA
Boat: Nauticat
Posts: 7,205
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Re: Skeg/Rudder Repair
Typical situation with the gudgeon bolts. The originals have too much corrosion on the bit of thread that actually engages for my taste, but cannot be replaced as they are metric and can only be sourced in up to 3" without waiting for a special order, time not available. Of course these are 3 1/4". So I go up a size to an SAE thread.
Original bolts vs new bolts depicted.
__________________
O you who turn the wheel and look to windward,
Consider Phlebas, who was once handsome and tall as you.
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02-02-2017, 22:07
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#32
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Resin Head
Join Date: Aug 2007
Location: Seattle WA
Boat: Nauticat
Posts: 7,205
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Re: Skeg/Rudder Repair
Installing these bolts was nigh on to impossible, as it became clear that at the factory they had pre drilled the gudgeon plates in a drill press and then welded them on to the gudgeon with less than perfect alignment. Since you cant use a drill press upside down on the bottom of a boat (mag drills don't work on fiberglass), this makes it impossible to drill through both of these beefy gudgeon plates without the bit following the path of least resistance on the original holes and bending a bit. Then you have to tap in this less than perfectly aligned pair of holes (only broke one tap!), and while the Italian glass work may not have been the best their metallurgy is superlative! Drilling and tapping in that gudgeon was like working with titanium. Very challenging. Got her done eventually, but only by extreme brute force methods. Things like a 1/2" NC tap in a brace and bit with hot cutting fluid. I had a brace and bit sized bruise on the center of my chest for two weeks after this session. Blood blisters came to the surface after a week or so. Truly I pity the fool who has to pull those bolts back out, how I got them all in without breaking one I don't know.
__________________
O you who turn the wheel and look to windward,
Consider Phlebas, who was once handsome and tall as you.
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02-02-2017, 22:14
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#33
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Resin Head
Join Date: Aug 2007
Location: Seattle WA
Boat: Nauticat
Posts: 7,205
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Re: Skeg/Rudder Repair
All done and splashed.
__________________
O you who turn the wheel and look to windward,
Consider Phlebas, who was once handsome and tall as you.
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02-02-2017, 22:25
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#34
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Resin Head
Join Date: Aug 2007
Location: Seattle WA
Boat: Nauticat
Posts: 7,205
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Re: Skeg/Rudder Repair
__________________
O you who turn the wheel and look to windward,
Consider Phlebas, who was once handsome and tall as you.
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02-02-2017, 22:54
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#35
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Moderator
Join Date: May 2008
Location: cruising SW Pacific
Boat: Jon Sayer 1-off 46 ft fract rig sloop strip plank in W Red Cedar
Posts: 21,150
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Re: Skeg/Rudder Repair
the usual fine job, Minaret! for the edification of the OP, could you tell how many of your highly skilled man hours were involved? Might be an eye-opener for him!
Jim
__________________
Jim and Ann s/v Insatiable II, lying Port Cygnet Tasmania once again.
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03-02-2017, 00:18
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#36
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Registered User
Join Date: Feb 2011
Location: Malaysia, Thailand
Boat: Beneteau Oceanis 430
Posts: 860
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Re: Skeg/Rudder Repair
Quote:
Originally Posted by minaret
Dunno why all pics I post with any iDevice come out rotated, they're upright when I post them.
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Didn't think I could contribute to this very interesting and great thread but here we go, hehe:
http://www.cruisersforum.com/forums/...os-178546.html
Thanks again for a great thread Minaret!
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03-02-2017, 01:09
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#37
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Moderator
Join Date: May 2008
Location: cruising SW Pacific
Boat: Jon Sayer 1-off 46 ft fract rig sloop strip plank in W Red Cedar
Posts: 21,150
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Re: Skeg/Rudder Repair
Quote:
Originally Posted by Jim Cate
the usual fine job, Minaret! for the edification of the OP, could you tell how many of your highly skilled man hours were involved? Might be an eye-opener for him!
Jim
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Hmm... I seem to have jumped threads here! I thought it was the one by the chap with the Cal 28.
sorry for the confusion, Minaret.
Jim
__________________
Jim and Ann s/v Insatiable II, lying Port Cygnet Tasmania once again.
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03-02-2017, 01:46
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#38
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Moderator
Join Date: Jul 2007
Boat: Bestevaer.
Posts: 14,678
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Re: Skeg/Rudder Repair
Minaret, I just wanted to add my vote of thanks for taking the trouble to post these photos.
Seeing how the pros do this sort of work is fascinating .
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03-02-2017, 06:24
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#39
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Resin Head
Join Date: Aug 2007
Location: Seattle WA
Boat: Nauticat
Posts: 7,205
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Re: Skeg/Rudder Repair
Quote:
Originally Posted by Jim Cate
Hmm... I seem to have jumped threads here! I thought it was the one by the chap with the Cal 28.
sorry for the confusion, Minaret.
Jim
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Ah, now I get it!
For the record, new rudder from Foss was about $2500 with shipping both ways, my end was about 10k all in what with materials and lay days, so about $12,500 to repair a busted off skeg and put in a new rudder. I think many of you are probably aware of what this might cost at yard rates; a whole lot more, and probably for less quality work. It took six weeks, but much of that was waiting for Foss. There's about four weeks of hours in there, for two guys. Thats about 320 hrs, or at the average yard rate of $100/hr; well, you do the math. Plus that's without materials, haul out, bill padding, etc. Tend to come in about 1/3 the cost of yard work, and about twice the quality!
__________________
O you who turn the wheel and look to windward,
Consider Phlebas, who was once handsome and tall as you.
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03-02-2017, 06:31
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#40
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Resin Head
Join Date: Aug 2007
Location: Seattle WA
Boat: Nauticat
Posts: 7,205
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Re: Skeg/Rudder Repair
Also for the record, there is another chapter to this story. I will post pics on it soon. Just got done hauling this boat back out and repairing the thirty years worth of mystery ghost problems on the inside of the skeg structure, a real Sherlock Holmes puzzler. Will post pics later, great example of the sort of weird stuff we run into. OP ran out of funds after the first round, he's a great guy who cruises heavily with wife and small kids. So I ate 32 hours and gave him my helper and tools at cost (with my guidance) to get it all done right and properly structurally sound. Ask your yard for a freebie and see what they say!
__________________
O you who turn the wheel and look to windward,
Consider Phlebas, who was once handsome and tall as you.
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03-02-2017, 06:43
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#41
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Registered User
Join Date: Jan 2010
Location: Port Ludlow Wa
Boat: Makela,Ingrid38,Idora
Posts: 2,050
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Re: Skeg/Rudder Repair
Heroics on the hard! Thanks for the pix. I'm surprised you didn't dismount that stuff and re do the holes with a torch:-).
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