Our boat is currently on the hard with the mast down, so no worries there. Incidently I checked on the marine plywood today at a local dealer and a 4 x 8 sheet of 1/2" is about $70. Looked online last nite for teak veneered marine plywood and they want a king's ransom. Not sure what I want to do yet as far as the material. One step a time!
Steve --- In [email protected], Dan Hardiman <hardiman...@...> wrote: > > 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 <scant...@...> wrote: > > From: Steve <scant...@...> > Subject: [IC27A] Re: Bulkhead replacement > To: [email protected] > Date: Thursday, May 20, 2010, 1:59 PM > > > > > > > > Â > > > > > > > > > > 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 <hardimandan@> wrote: > > > > > > I replaced mine about 7 years ago.ÃÂ 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.ÃÂ 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 duringÃÂ reassembly.ÃÂ 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.ÃÂ For the star board bulkhead I used true marine grade plywood > > that set me back about $150.ÃÂ I still have the marine grade port > > bulkhead cut out in the shed.ÃÂ In retrospect if I had to do this again, > > I probably would not use the marine grade plywood.ÃÂ 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 > > > > > > > > > > > > ÃÂ > > > > > > > > > > > > --- On Thu, 5/20/10, Steve <scantino@> wrote: > > > > > > From: Steve <scantino@> > > > Subject: [IC27A] Re: Bulkhead replacement > > > To: [email protected] > > > Date: Thursday, May 20, 2010, 9:36 AM > > > > > > > > > > > > > > > > > > > > > > > > ÃÂ > > > > > > > > > > > > > > > > > > > > > > > > > > > > > > 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 > > > > > > > > > > > > > > > > > > >
