Big problem with 1987 Catalina 27'

[davidpm]

After a minor grounding, just a touch actually we developed a leak least summer. Ground it out a bit and reglassed.
This spring the lift operator noticed a bad noise and the boat took on water again.
We ground it again and the glass we put in was solid but we see more blank goop.
Pictures follow.
Is this boat repairable, how?

[uspirate]

thats nasty, well the saying goes "if it's fiberglass, it can be repaired" looks like a job for a pro.

[denby]

Is the keel solid lead or encapsulated in glass?

[US27inKS]

It looks like you have at least 2 voids in the hull. In picture 3 you have one on the keel stub, and one to port of that. I will agree with USPirate, looks like a job for a pro. Of course I'm never one to follow my own advice, so I would get out the grinder and have at it until the voids are gone. You will likely have a large hole or two in your boat when you're done. Then it's time for a few gallons of epoxy, the appropriate fiberglass for the job, and fillers for fairing later. Don't forget the barrier coat before the bottom paint goes back on.

[SimonV]

Get in a professional. I think you could very quickly make things a lot worse than they are now.

[Maine Sail]

Originally Posted by SimonV

Get in a professional. I think you could very quickly make things a lot worse than they are now.

You need a professional that prior patch was clearly done without knowledge of structural fiberglass repair.

There is a big difference between cosmetic repair (which the previous one was) and structural. You also should check your stringers. It's possible one is cracked and no matter what you do for repair if a stringer is cracked it will create future issues..

[Sailormann]

After a minor grounding, just a touch actually we developed a leak least summer. Ground it out a bit and reglassed. This spring the lift operator noticed a bad noise and the boat took on water again. We ground it again and the glass we put in was solid but we see more blank goop. Pictures follow. Is this boat repairable, how?

Unfortunately the damage has occurred in an area that sees a fair amount of stress. In order to repair it, you are going to have to open the boat up about 6 feet on either end of the keel (fore and aft) in order to replace the roving that is there. The keel loading needs to be spread over the hull as much as possible, and this happens via the hull structure itself, and also partly through the stringers. The long pieces of roving transmit a fair amount of this loading through the hull. Doing a spot repair doesn't do much except plug the hole, and then when the keel starts to flex, the repair material works its way out of the hole and you're back to square one.

I don't know what yard charges are like in your area, but up here, I would expect to pay well north of 10K to have that fixed. Even then, I would have doubts about the seaworthiness of the boat, because the repair will be done with resins that are probably stiffer and stronger than the original hull, and the adhesion between the new and the old may not be that great.

I don't know how much you have invested in the boat, but my advice would be to claim as much as you can from your insurance company and walk away from her. Sad event I know but it's hard to think that the boat will ever be safe again.

Good Luck !

[davidpm]

Originally Posted by denby

Is the keel solid lead or encapsulated in glass?

The Catalina 27 has a small glass keel about 12" which houses the bilge then the lead keel is bolted to a piece of plywood in the bottom of the bilge that is encapsulated in glass.

[davidpm]

Originally Posted by halekai36

You need a professional that prior patch was clearly done without knowledge of structural fiberglass repair.

There is a big difference between cosmetic repair (which the previous one was) and structural. You also should check your stringers. It's possible one is cracked and no matter what you do for repair if a stringer is cracked it will create future issues..

What do you mean. The previous repair had several layers of cloth. What else should have been done.
I donn't belive the Catalina 27 has stingers. Tell me exactly what to look for.

[camaraderie]

David...I am thinking the black goop is the plywood. You need to drop the keel...effect repairs to the keel stub...replace the plywood with stainless...make the repairs to the keel....and bolt it all back together. You may also have keel bolt damage, but likely it is just the plywood.
Good luck!

BTW...I think Halekai is referring to the fact that you are repairing a very heavy, load bearing surface that is under considerable stress in use. This means your repair needs may need to be extended quite a bit both internally and externally to provide the proper bond and support. Obviously the right materials and prep job must also be done, but I assume you did that before making your repair. To me..the repair looks more of a "patch" than a structural repair....but it is very tough to tell from mere pictures.