Cal 20 Discussion Forums

Hi Steve,

I put up some photos I took here:

http://www.flickr.com/photos/28160454@N08/sets/72157622975642397/

The boat had sat for a couple of years with the PO and he paid to have it hauled away.  The hauler of course tried to sell it, and hooked me.  Good thing I didn't know what I was in for, but it has been very interesting, and I've had two very enjoyable seasons with the boat.

Briefly, removed the support posts (cast aluminum braces on the lower ends both were trash from corrosion) removed mahogany support beam, stripped 2/3 thirds of the deck core, sanded, rebuilt core under mast, faired the deck surface, applied new deck core in workable sections, and glassed it all back in.  Plastic shopping bags make great hair protection, otherwise you end up with Helmet hair, very tough to comb.

I did mine in January, February, and used an electric portable space heater to keep the insides warm enough for the expoxy to set, (I'm in RI).

The deck support I used (in photos) kept the deck in alignment and the mahogany support beam fit back into place just fine (had new stainless braces made for the posts).

For my winter cockpit cover, I drilled one inch holes in two 2x4's, set one on each side of the cockpit, bent 1"pvc 10' pipe into an arch, about seven arches, and then just covered everything with a tarp, climb in an out of the back on the ladder.

Take care,

cb

Hi Steve,

Thanks for the complements about the interior photographs.

I used 1/4" inch 3 ply marine grade plywood for the core material as I thought I'd be able to bend it easier than the thicker stuff.  The deck feels very solid now.  When I re-attached the deck hardware, I drilled oversize holes and plugged then with epoxy and filler, let it set and then drilled the correct size hole.  Then I used a counter sink to put a bit of a bevel on the hole through the epoxy to mount the hardware.  Hopefully this will prevent future core problems.  No leaks after two seasons...

  The portable space heater was left plugged in for the duration of the job, nice electric bill that month!  It's a newer model that shut off if it detects it's been tipped over, and a thermostat of course.  There was enough natural air circulation and overheating wasn't a concern.

I found that I just had to start the job, and focus on one step at a time.  I just butt edged the plywood in the natural sections that the shape of the deck presented (hatch opening, entry way opening), and yes it was a messy job.  I'd cover everything inside with a tarp and tape plastic to the hull to make drip removal easier.  I sanded a lot when finished...

I need to replaced the plywood flooring the runs on each side of the keel, just waiting to buy another tool to cut the fiberglass tabbing...

Take care,

cb