Keel Repair

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8 years 8 months ago #2102 by William Weigel
Keel Repair was created by William Weigel
We had the misfortune of hitting a rock yesterday near Roque Island in Maine. We have a 4" x6" chunk of glass broken out about 1 foot up from the bottom of the keel. Lead is showing. I plan to haul out in about 2 weeks to repair. Does anyone know if there is a void around the ballast? How much water will I need to try to drain out of the keel?

Thanks in advance.

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8 years 8 months ago - 8 years 8 months ago #2103 by Gerry O'Donoghue
Replied by Gerry O'Donoghue on topic Keel Repair


As you can see from the diagram above the forward lead ballast is in its own "compartment" forward of fuel tanks. I'm pretty sure that it was a lead casting that was dropped in place and glassed over (If anyone has info that they were poured in place let me know). There may be small voids around the lead but this should not be a big issue.

1. Drill a drain hole on the foot of the keel under the damage to see if any water drains out. I doubt if it would be a major amount.

2. Grind away the damaged area using Don Casey's 12:1 bevel info; www.boatus.com/boattech/casey/fiberglass-repair.asp
I would use West System Epoxy.

3. Patch up drain hole.

Not a major deal with a full keel boat like a Whitby/Brewer. Don't try hitting the same rock with a modern production boat.

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Last edit: 8 years 8 months ago by Gerry O'Donoghue.

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8 years 8 months ago #2104 by Scott Lee
Replied by Scott Lee on topic Keel Repair
Is it possible that concrete was involved with setting the lead in the keel? Maybe poured in around the lead casting? In kleening up my bilge under the former water tanks I ground off a bubble that exposed a concrete looking substance under the glass. The spot is patched now and I wasn't curious enough at the time to open it further for verification.

Scott

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8 years 8 months ago #2105 by Scott Lee
Replied by Scott Lee on topic Keel Repair
photographic evidence...

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8 years 8 months ago #2106 by David Groves
Replied by David Groves on topic Keel Repair
Hi All
Shamal has had extensive experience with this topic.
Conversations with Doug Stephenson in the past revealed the construction of the hull of the W42 was as follows.
Hull halves including keel were laid down separately. The two halves were bonded with thick fibreglass mat and roving on the interior of thehull and keel section, leaving a space for ballast. Two pieces of precast lead, parallelograms, approx 4000 lbs each, were placed inside the keel area, forward. The centre fuel tank and additional lead aft for bowsprit boats were also added. Foam blocks were used to centre the lead, tank, etc and then seacrete? was poured into the voids to immobilize the ballast. The whole thing was glassed in, I think. There is a photo of our hull at this stage on the website.
On the outside, the join was just faired, leaving a weak point for water entry and weakening of the keel.
Will follow up with another note about solutions.
Fair winds to all
David
Shamal
W42#321

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8 years 8 months ago #2107 by Gerry O'Donoghue
Replied by Gerry O'Donoghue on topic Keel Repair
Great information David. I had not known about the seacrete but that ties in with building practices of that era.

Just a note, the two halves of the hull were joined with SEVEN (I believe) layers of glass fiber on the inside and these were extended well up from the join. The outside seam was filled with dolphinite bedding compound or similar. If there is some damage here, water can get into to the seam but not into the hull unless you have a major breach.

There is a brief article on the Kelly Peterson 44 web site which has similar construction.

www.kp44.org/rudders/hull_seam_voids.php

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