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Re: Rust in encapsulated keel?!
Once steel/iron begins to rust that formation of ferric oxide which is less dense that the original material will develop extreme pressure within that encapsulation. Structurally, all that fiberglass in the area of the keel is now suspect to be in failure, as evidenced by the weeping of rust coming through the side walls of the encapsulation. To fix it, all the fiberglass should be entirely removed and the iron/steel portion be 'rehabilitated' or replaced, the encapsulation and its repair should then be verified so that water migration and permeation at less than 'visual' level should be considered .... a "Massive" job to be done to insure the structural integrity of that encapsulation. Without a complete removal and total rebuild the confidence level that this iron keel ballast would not continue to degrade and 'push' apart any repair ... that confidence level should be low. Without such complete repair there would be a high probability that the rusting iron in future would simply continue to 'expand' causing failure of the encapsulation and possible catastrophic loss and release of the iron out the bottom.
So, from that starting point of a totally complete removal and total rebuild including new encapsulation to OEM structural equivalence, you should be able to do a cost and time estimate. That old iron has to be inspected and probably replaced, and a whole new fiberglass keel (ballast section) built from scratch --- or the confidence of the repair integrity will remain very low.
Last edited by RichH; 07-18-2014 at 12:41 PM.