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Seafarer 37 major repair
Hi there, I am new to the forum, but will likely be a mega-poster by the time I have completed this repair. My SF37 dragged her mooring in a storm last year and suffered significant damage to the fin keel, skeg (gone), rudder, and prop shaft. The insurer offered a choice: total out, or take 85% payout and keep boat as is for repairs. Probably not the smartest decision of my life, but I took option B and am just now getting started with the project.
Phase 1 will be keel repair. The encapsulated keel consists of solid lead which was poured to fill the void from the leading edge to a point about 25" forward of the trailing edge. Though exposed and slightly scratched up, the lead is essentially undamaged. the 25" from aft of the lead to the trailing edge of the keel originally consisted of some sort of resin mixed with filler (almost looks like sawdust). It is this area that needs reconstruction... I will construct a sheet metal mold and re-pour this "core", if you want to call it that. I am not sure what to use for resin/filler. In my opinion epoxy would be overkill. The structural strength will ultimately come from the fiberglass laminate over this area and the lead portion which I plan on using epoxy for. I am leaning toward a more inexpensive polyester resin with who knows what for a filler. The better commercial fillers again seems like overkill for this... my rough calculations say that this void will take 4-5 gallons of fill. I have a bunch of the old filler in chunks as well as a bunch of the old laminate that I have ground off. What about just chopping all this material up as filler? Any other ideas? I'm not looking to cheap-out on a very important repair, but how much is too much?
I will attach a few photos to better show the damage, the area to be repaired now that I have cleaned it up a bit, and a couple of close-ups of the old filler.
Thanks for your thoughts!