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Discussion Starter #1
I had a kind of eventful haulout. Several unexpected repairs came up, in addition to the expected tasks of maintaining the cast iron keel. I sanded down the keel to the last good epoxy coat and applied 4 coats of interprotect, followed by antifouling. In a couple spots though, water seepage was found to come through my interprotect, requiring me to drill in like a dentist with the dremel tool till the soft rusted metal was gone and filled the voids with thickened westsystem before recoating with interprotect & antifouling.

Well about 4 or 5 of these areas came up and I must be a complete idiot because I ground out the rust in all the areas but forgot to fill two of them (they were small and on the edge of the keel near the keel to hull joint). I guess those two spots are about the size of a nickel and about 1/4" deep.

Now I'm back in the saltwater marina.

Does anyone have a guess as to how fast these two little spots will rust and how much bigger the corroded area will be in a year's time?

Does it warrant another haulout promptly or could I repair it with underwater epoxy? I wouldn't look forward to a swim in the Puget Sound any time of year, but compared with another $$$ haulout and even worse the humiliation from the fiancee it could be a better option.

Does anyone think underwater epoxy (someone mentioned flexset) would actually stick to iron underwater and would do any good to prevent corrosion for a year or so? I guess I would have to prep the spots with wire brush and apply the epoxy immediately.

or would such small areas not rust fast enough to worry about at all considering the size of the keel (8500lbs)

Appreciate any advice!
 

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My guess would be the areas may double in size in a year, if they are surrounded by well-adhered epoxy. I would not worry about the areas until our next haul, all that will happen to them is the rusting surface finish.
 

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I would like to add to this question:

Aren't there any paints, tar or whatever out on the market that can be applied
underwater, to give some protection ?

I mean, they can't haul out these old metal seawalls they have in some harbors ? They are welding them underwater, so I would assume it's possible to get some protection onto the metal (or the fiberglass in our case) ?

I have some scratched areas (keel scratching rock :( :eek: ), that I would like to give some protection.

Any ideas or hints we could follow ?

tnx
 

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Underwater curing epoxy putty. :)
 

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Does it warrant another haulout promptly or could I repair it with underwater epoxy?
I certainly wouldn't recommend hauling again for this. The keel is going to rust to some degree no matter what you do to it now. Maybe have a diver slap some underwater epoxy on the spots if you can't sleep nights thinking about it but other than that, rust repairs are a fact of life with externally ballasted iron keels. You may as well wait until she needs new paint again to deal with it, IMHO.
 
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