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Old 02-02-2017, 21:57   #31
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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.
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Old 02-02-2017, 22:07   #32
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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.
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Old 02-02-2017, 22:14   #33
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Re: Skeg/Rudder Repair

All done and splashed.
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Old 02-02-2017, 22:25   #34
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Re: Skeg/Rudder Repair

Link to article on this repair.



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Old 02-02-2017, 22:54   #35
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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!

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Old 03-02-2017, 00:18   #36
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Re: Skeg/Rudder Repair

Quote:
Originally Posted by minaret View Post
Dunno why all pics I post with any iDevice come out rotated, they're upright when I post them.
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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Old 03-02-2017, 01:09   #37
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Re: Skeg/Rudder Repair

Quote:
Originally Posted by Jim Cate View Post
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
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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Old 03-02-2017, 01:46   #38
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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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Old 03-02-2017, 06:24   #39
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Re: Skeg/Rudder Repair

Quote:
Originally Posted by Jim Cate View Post
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

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!
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Old 03-02-2017, 06:31   #40
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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!
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Old 03-02-2017, 06:43   #41
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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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