Michael,
It sounds like something got loose in the (sand) casting process. The molds
are hard packed sand so if a section got knocked off in the filling process
it might get encapsulated in lead. If it subsequently got wet I could see a
bulge forming.
I'd try to clean out the sand without removing the lead shell. Until you
know the size of the void I'm not sure you should settle on a solution.
Filling with lead shot and west systems epoxy sounds goods but without
knowing the real size of the void any recommendation would be premature.
Phil Agur
----- Original Message -----
From: "Michael DeFazio" <[EMAIL PROTECTED]>
To: <[email protected]>
Sent: Monday, March 03, 2008 5:12 PM
Subject: catalina27-talk: Keel Problem
I have a 1981 Catalina 27. There is a bulge in the
center of the port side of the keel. It is about 10
inches long and about 12 inches high and protrudes
about 1 inch from the side of the keel. In an attempt
to repair it, the boat yard cut it open and found that
the keel is full of sand. The bulge contained loose
sand but the remainder of the sand within the keel is
packed very hard. The sand appears to be encased by a
lead shell about one quarter of an inch thick which
forms the keel with fiberglass and epoxy fairing over
the lead. Has anyone ever heard of this before? Any
suggestions for repair?
