Steve, I forgot to add that we did the bulkhead replacement with the boat in the water and the rig up.
~Dan --- On Thu, 5/20/10, Steve <[email protected]> wrote: From: Steve <[email protected]> Subject: [IC27A] Re: Bulkhead replacement To: [email protected] Date: Thursday, May 20, 2010, 1:59 PM Dan, What year is your boat? There are some distinct differences in the models over the years. I've read some post by others who have tackle this but their boats were 70's models. The bulkhead is seated in the molded fiberglass channel in the cabin roof and side of the hull. The compression post also has a channel that the bulkhead seats into. There is no way to remove the bulkhead without taking the post out. I'd like to see some pictures from anyone who has done this on a mid to late eighties model. Steve --- In [email protected], Dan Hardiman <hardiman...@...> wrote: > > I replaced mine about 7 years ago. My step-father and I did not remove the > compression post, I can't imagine why you would want to unless it is rotted > at the bottom. There are A LOT of screws involved, we attached a small > piece of masking tape to each one and numbered the tape and the holes with a > Sharpie for ease of reference during reassembly. I would say the entire > process of removal, cutting, and reinstallation took us about 5 hours. > > Incidentally, the port bulkhead needed to be replaced on short notice before > a race so it is made from a piece of furniture/project grade plywood. For > the star board bulkhead I used true marine grade plywood that set me back > about $150. I still have the marine grade port bulkhead cut out in the > shed. In retrospect if I had to do this again, I probably would not use the > marine grade plywood. I believe sealing the edges with epoxy and ensuring > that the chain plates don't leak is more important. > > Dan Hardiman > C27 #4149 Summer Skis > Annapolis, MD > > > >  > > > > --- On Thu, 5/20/10, Steve <scant...@...> wrote: > > From: Steve <scant...@...> > Subject: [IC27A] Re: Bulkhead replacement > To: [email protected] > Date: Thursday, May 20, 2010, 9:36 AM > > > > > > > >  > > > > > > > > > > Many thanks for the information. I'll try to document this task with a > camera, it may prove helpful to someone else in the future. > > Won't be able to attempt this fix for a few weeks but will definetly repost > when I tackle it. > > I was surprised when the tech told me that the interior was installed after > the mating of the deck to the hull. I assumed the interior was fabricated and > installed prior to the deck being mated. > > Didn't think there was any way to get that out without destroying it in the > process. > > 2 to 3" sounds like a lot. Did the deck experience any damage from the > jacking? Did you seal the edges of the new panel before installing it? > > > > Steve > > > > --- In [email protected], JWambo8566@ wrote: > > > > > > I remember being surprised when I received a call back from Catalina. The > > > day before I left a message stating that I was looking for information on > > > how to remove the bulkhead. I was told that someone would call me back. > > The > > > very next day I received a phone call from Gerry Douglas, vice president > > and > > > head engineer of Catalina. He was very nice and answered every question I > > > had. > > > > > > You have to raise the ceiling more than you would think. If I remember > > > right it was around 2-3 inches. The compression post needs to clear the > > > recesses on the ceiling. Once it was clear, I tilted the top of the post > > out and > > > lifted the bottom out. Neither the compression post nor the bulkhead was > > > fastened to anything else or each other. Everything just fit tightly > > > together. > > > When removing the compression post, the small panel next to the head door > > > also just slips in and out. Sort of like fitting a puzzle together. You > > just > > > sort of have to figure the best way as you go along. > > > At the time, the only teak plywood that I could get was imported from > > > Greece and was metric. It seemed bigger that 1/2 inch but smaller than 3/4. > > > > > > Looking back, I'm still am amazed at the procedure and how much the boat > > > actually flexed. I can't emphasize enough about the care you must take > > around > > > the jack and the 2X4's. While under that much pressure, resting on a > > > curved floor, propped on a slippery top, when they slipped, they flew. Be > > > careful and take your time. The foam rubber in between sounds like a good > > idea. > > > > > > Good Luck. > > > > > > John Wamboldt > > > C27 #6287 > > > ZuZu's Petals > > > Lake Michigan > > > > > > > > > > > > In a message dated 5/19/2010 9:11:54 P.M. Central Daylight Time, > > > scantino@ writes: > > > > > > > > > > > > > > > John, > > > > > > Funny, I talked to Catalina today and the tech I spoke to didn't have a > > > clue. His suggestion was to pose the question on this forum. > > > How much room did it require to slip the compression post out. Are we > > > talking an inch, 1/2" or less. It's hard to tell how much the recess is in > > the > > > top and bottom pockets. > > > Did you lift up and out or simply pull it out once the cabin ceiling was > > > clear? > > > I mentioned the bungs on the table side of the compression post. Are there > > > screws anchoring the bulkhead inside the channel of the compression post? > > > Does the small panel attached 90 degrees to the comp. post get removed > > > separately. Talking about the side the head door closes to. > > > > > > 1/2" plywood is the correct thickness? > > > > > > Thank you for the information. > > > > > > Steve > > > > > > --- In [email protected]_ (mailto:[email protected]) , > > > JWambo8566@ wrote: > > > > > > > > I did this job about 10 years ago on my 1986 C27. I spoke to Catalina > > > how > > > > to remove the bulkhead and followed their directions even though it > > > sounded > > > > crazy, and dangerous. > > > > > > > > The mast must be down. > > > > Remove everything that attaches to both sides of the bulkhead. Table, > > > > shroud plates, medicine cabinet; everything. Then comes the scary part. > > > Using a > > > > 2X4 placed on top of a small hydraulic jack, placed near the compression > > > > post, slowly jack up the cabin top, I placed a small piece of wood under > > > > the jack to spread out the load on he floor. When jacking, be very > > > careful > > > > because the 2X4 or the jack can slip very easily and it fly's out with a > > > lot > > > > of force. Trust me, it happened a couple of times until I got it > > > positioned > > > > just right. While jacking, the boat creeks and groans something fierce. > > > > Keep jacking until the fiberglass around the compression post is just > > > high > > > > enough to tilt the top of the compression post out. Once the post is > > > out, you > > > > can then slide the entire bulkhead out. Again, use a lot of care not to > > > jar > > > > the 2X4 while removing the bulkhead. Once the bulkhead is out, you can > > > let > > > > the jack down until the new bulkhead is ready to be put back in place. > > > > I took a piece of marine grade teak plywood and the old bulkhead to the > > > > cabinet maker that made my kitchen cabinets. He was able to cut the new > > > > bulkhead using the old one as a template. He also was able to match and > > > apply the > > > > laminate to the head side of the bulkhead. He matched it perfectly. He > > > > told me that the bulkhead has seven different compound miter cuts. That > > > alone > > > > made it worthwhile having him fabricate it. Very minor sanding made it > > > fit > > > > perfectly. You just jack up the cabin top and install everything in > > > > reverse. By the way, I used Cetol on the cabin side of the bulkhead and > > > it matched > > > > almost perfectly to the rest of the factory stained wood. Also, it's a > > > > good time to run any new wires you need up the compression post and out > > > the > > > > top. > > > > > > > > I know this whole thing sounds crazy, but trust me, it just took a lot > > > of > > > > guts, planning and care. I gave you the real quick explanation, let me > > > know > > > > if you need any more detail. > > > > > > > > > > > > John Wamboldt > > > > C27 #6287 > > > > ZuZu's Petals > > > > Lake Michigan > > > > > > > > > > > > > > > > > > > > In a message dated 5/19/2010 4:10:04 P.M. Central Daylight Time, > > > > scantino@ writes: > > > > > > > > > > > > > > > > > > > > I've search archives for information related to replacing the starboard > > > > bulkhead on a mid eighties catalina 27. > > > > I have an 87' that needs a new bulkhead. > > > > Has anyone documented their effort to replace a late model 27's > > > starboard > > > > bulkhead? > > > > I don't want to quess and start removing parts randomly. > > > > It appears that a least a portion of the compression post might have to > > > be > > > > removed in order to slide the bulkhead out. > > > > The post looks to be four pieces of solid wood lamenated together. There > > > > are four bungs visible on the side of the post next to the drop down > > > table. > > > > I'm assuming these hide the screws that anchor the bulkhead to the post. > > > > Can the post be removed to allow access to the bulkhead? Looking for > > > some > > > > help! > > > > > > > > Steve > > > > > > > >
