Bart,
Have you put a magnet up against your keel to figure out if it is cast iron or lead? If it is lead then you can reinforce it the keel fasteners with 1/2" x 10" lag bolts, pre-drilling with a 27/64" drill bit. If it is cast iron, then drilling and tapping for the 1/2" mild all thread is the way to go. Installing 4 lag bolts / all thread rod would help reinforce the keel joint. I would not recommend trying to weld stainless to the mild keel bolt as you will still get electrolysis at the weld and it will most likely fail again. Attached is the installation drawing for the keels should you decide to remove your keel and reinstall it. All of the people I have talked to have said that even with the keel bolt nuts backed off and the boat in the air, they have had to used wedges and sledge hammers to break the keel loose, so it is on there really well. However, since your keel is canted to one side it might be worth the effort to remove and reinstall it.
Good Sailing,
Kent Nelson Engineering Department
Catalina Yachts
21200 Victory Blvd.
Woodland Hills, CA 91367
(818) 884-7700 ext. 237
(818) 884-3810 Fax
kent@catalinayachts.com
www.catalinayachts.com
Looks like this might be an easier fix that I originally thought.
I will first drill and tap for a 1/2" threaded rod just forward of the broken keel bolt.
Will probably need a right angle drill to perform this.
I will then drop the keel, and re-bed it, filling the broken bolt hole with epoxy.
Want to do this sooner than later.
I don't want to be rushing this before launch next year.
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