Chip Ford's 1974 Catalina 22 Restoration Project
Sail #3282  l  Marblehead, Massachusetts

The never-ending project to fill my hole in the ocean while bailing it out

The Keel "Thunk" Repair Project (2007-08)
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Click thumbnails for a larger picture


Chip Ahoy in the sling, the repaired keel beneath on the fork lift ready to hang.  (Apr. 26, 2008)

Chip Ahoy in the sling, the repaired keel beneath on the fork lift ready to hang.

Chip Ahoy in the sling, the repaired keel beneath on the fork lift ready to hang.

The repaired keel almost ready to hang.  Unfortunately, Tommy drilled for the new zinc plate a fraction of an inch too close to the keel pin bushing.  He had to remove the plate and cut a bit off to fit when the keel is in the down position.

[Closeup Detail]

The keel slot and weldments, clean and ready to be put to use.

[Closeup Detail]

The keel hanger, its new bushing and bronze pin.

A view of the keel hanger with its pin inserted.

The keel test-hung for fit.

The keel lowered.  This is when we discovered the zinc plate needed to be removed, cut to fit.

The keel hangers installed with their new pin.

The shackle on the end of the new keel cable fork looked unnecessary.  Apparently it's been there since the first keel refinishing project.  That shackle was first used to suspend the keel temporarily while it was being worked on by the boatyard back in 2004, but was never removed.  I wondered about it belonging there when I replaced the cable.  I questioned Tommy, and did some research on this website, documented how it was originally connected before the yard restored it.  He'll make it right when he again lowers the keel.  (Apr. 26, 2008)

Tommy added thickened epoxy in the keel slot just forward of the cable access hole to remove any residual side-to-side movement of the keel while in its up position -- the likely cause of the thunking and worn pins.  The keel was raised into the soft epoxy to create its shape.  Chip Ahoy was lowered back onto its trailer while the epoxy filler covered with waxed paper cures and hardens.  (Apr. 27, 2008)

[Closeup Detail]

The rain that started falling on Saturday finally stopped last night, so the boatyard got back to work on Chip Ahoy this morning, Wednesday.  The extraneous shackle was removed from the keel cable fork, a notch was ground out around the eyebolt, and the fork was attached properly -- after all those years.  (Apr. 30, 2008)

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It's never-ending ... but Sailing Season '08 is coming fast!

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