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post #7 of Old 03-23-2010
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Smile Lead Keel Problem

Hey folks you’re on track. The 272 and other models used the lead keel attached by three 1" bolts to the stub accessible from the bilge. My recently purchased 88' 272 had very bad problems with the keel, the worst I ran into. The purchase price at 3.5k was reflective so all was OK.

The red is NOT the epoxy covering but chemical reaction to the lead, salt water, epoxy and time or neglect. I was able to scrap out large chunks and the weight of it said lead not epoxy.

Key to proper and safe repairs - #1 purchase a respirator not a dust mask, this is bad stuff for the lungs during the repair. The epoxy is also bad stuff when sanded or ground. #2 Purchase an inexpensive sand blaster at the local auto store, $50. #3 purchase disposable cover-alls, hood goggles and gloves. Inexpensive tyvek is best $40. Spread an old tarp under the repair area as you want to capture all the bad stuff.

The repair - with 4" grinder #60 paper and dressed for combat start removing all that is discolored down to bright lead. Remove epoxy 4" above the damaged area moving upward on the keel. Once you have done as much damage as possible with the grinder get the sand blaster in hand and remove all discolored in the nooks that the grinder could get to. Day #2 - With epoxy paint made for bellow the water line ready to mix blast one more time, mix the epoxy paint and thin. Apply one thin coat and follow the directions for three to five additional coats to achive 3-4 mil. This will protect the lead from additional damage and preserve what you have. Day #3 or #4, sand or blast area lightly with #80 and wash. When dry mix bellow the water line epoxy, apply all the coats required to build beyond the area and beyond the height of damage as you will need to fair (sand) this at the end. Once cured fair as required to achieve the original look. Day #5 or #6, Back to epoxy paint as above to achieve 8-10 mil. Remember to follow the directions for set time and most important on the last coat, when finger print dry add a coat of bottom paint. That last steep bonds the two together.

In a perfect world I would have unbolted and dropped the keel for bench repair but breaking the factory seal is iffy. Total cost $250.00. Total time one week on and off. Total mess - crap it was awful. Prior experience - 10 years, 20 years ago. If you are faint hearted, don't have the tools, don't do it, spend the grand and hire it out.

2 qts of epoxy paint intended for bellow the water line
2 qts of epoxy intended for bellow the water line. (use thick set)
12 qt mixing cups
24 paint stir's
12 disposable 1 1/2" brushes
6 plastic epoxy spreaders 1 1/2" wide or so.
1 pint of thiner for the epoxy paint (use the recomended)
rags, rags and more rags.
FreeportMaine272 is offline  
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