Hi Henry,
What year boat?
On item one, my personal preference is epoxy, although polyester would obviously work.
On item 2 I assume it is not at the hull-keel crack.  I would open this up and see if there are any problems underneath.  Epoxy fairing material could be used to close it up.
On item 3, I have a similar problem of the aft end of the rudder approaching the hull. My rudder does not hit the hull, but comes very close.  It was caused by a severe grounding by the PO. But in 17 years it hasn't changed.  My bet is that your will need a new rudder.
I can't account for the vertical movement of the rudder.  You might inspect the rudder post thru hull very carefully.  The rubber washer seems to serve no purpose.
I'll have to try to see if my rudder has any vertical movement.
Let us know what happens.
Harvey Rosenberg, 27TR, #6023, 1985, M-18, Stony Point, NY




------ Original Message ------
Received: Sun, 09 Apr 2006 10:35:37 PM EDT
From: "Henry Hubbard" <[EMAIL PROTECTED]>
To:
Subject: catalina27-talk: Hull, Keel, Rudder Questions


My Catalina 27 was hauled ten days ago with the intention of bottom paint and thru hull inspection and seacock replacement. When looking at the bottom and keel today I noticed
 
1) a few places which, evidently during starting to scrape, had chipped -  maybe the gelcoat? Where it was chipped, about as deep as a CD thickness or less, there is exposed fiberglass, with fibers evident. From the "This Old Boat" book I gather that these can be filled with polyester resin and then painted over with bottom paint. Does this sound right?
 
2) on the keel, about two-thirds of the way down on the side, there is a big crack that looks like plastic material - about a quarter inch thick -(fiberglass?) is separating from the material (metal? steel? lead?) underneath. It sounds hollow in an area about the size of two hands or so, but knocks like solid metal elsewhere. It looks like it's new. Is this something that may have been caused by setting it on the keel? Can anyone direct me to information on how to repair?
 
3) The rudder and shaft will move up and down so that the top of the rudder rubs the boat bottom, right at the very aft end, and there is evidence of wear where this has occurred. When the rudder is turned, the vertical travel stops befor the rudder near the shaft engages the bottom where the shaft enters. As the rudder hangs there is about one-half to three quarters of an inch of shaft showing and it has a rubber washer around the shaft about an eighth thick, which, in the current configuration, serves no purpose. What is supposed to stop/secure the rudder and shaft from vertical movement? Is there a spacer missing? Maybe the shaft is bent?
 
I would appreciate any commentary from those who may have knowlege in these areas.
 
Thanks,

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