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Catalina/Capri 25/250 Sailor's Forums

Catalina 25 Specific Forum

Bulkhead Replacement

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Rich P
1st Mate

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USA
77 Posts

Initially Posted - 12/03/2008 : 07:49:48

The chain plate on the port bulkhead (just aft of the head) looks like it pulled about an inch. Would it be OK to remove the mounting hardware and then through bolt some wood to make new holes to mount the plate or should the bulkhead be replaced? I'm leaning toward replacement and wondering how much of a project this would be as well as what to use to keep it looking original.

Edited by - on

pastmember
Master Marine Consultant

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2402 Posts

Response Posted - 12/03/2008 : 08:38:11

Holly Crap! Can you post some photos? I would replace the bulkhead and would call Catalina parts to see if they could help me with materials. Do this right! Who would buy a boat whose main bulkhead did not look strong!

Edited by - on

Steve Milby
Past Commodore

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USA
5908 Posts

Response Posted - 12/03/2008 : 09:39:23

Some people have replaced their bulkheads - Duane Wolff comes to mind. Maybe he'll chime in.

I don't know how expensive a new bulkhead would cost from Catalina, but their prices generally aren't too bad, so it's worth checking. As an alternative, I believe marine plywood has been used. It's certainly sturdy enough. For aesthetics, I don't know why you couldn't veneer the plywood with a kitchen cabinet wood veneer. Cherry or birch or oak would could have a nice warm look. You could even use something like plain white or off-white formica, which would be easy to clean and brighten the interior. There are options, depending on how much time, labor and money you're willing to invest.

Edited by - on

dmpilc
Master Marine Consultant

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USA
4593 Posts

Response Posted - 12/03/2008 : 10:00:53

Were you in any major weather to cause that, or do you think it was due to flexing over a long period of time? Seems like a lot of movement.
There was a 1981 C-25 on Ebay (auction ended yesterday)that looked like it had oversized chainplates on both bulkheads (or else I just don't remember what mine look like) which appeared to be about 3" wide. Perhaps you could do that with a different bolthole alignment that would give you new holes and cover up the old ones, without replacing the bulkhead.
Otherwise I would also suggest that you call the Catalina factory and see about ordering a relacement.
I have replaced the starboard bulkhead in our C-22, using the original one as a template. It's not hard to do, but that was a much smaller piece of wood. I used 1/2" plywood, wood putty on the edges, and many coats of varnish all around. That was going to be only temporary because I also took the original to a nearby boatyard and had a guy there make a new one with the same trim on the edge, but it's still in my garage now several years later as a backup for when the "temporary" homemade one gives out.

Correction, the 81 on ebay has been relisted so you can see the pics.

Edited by - dmpilc on 12/03/2008 10:11:07

Dave5041
Former Mainsheet Editor

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USA
3758 Posts

Response Posted - 12/03/2008 : 10:07:58

It should be straightforward. Take the old one out carefully and use it as a pattern for a new one on 1/4" plywood to check the fit. You can staple heavy pasteboard on it to adjust the edges in areas that don't contact the interior fiberglass to produce a pattern to cut the new one on veneered (mine looks like mahogany) marine plywood. Use marine plywood because it doesn't have internal voids and the bulkhead is structural.

Edited by - on

Prospector
Master Marine Consultant

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Canada
3159 Posts

Response Posted - 12/03/2008 : 11:09:22

Friends of ours had new chainplates installed in their C-27. Due to rot in the bulkhead, they had a section scrfed into the existing bulkhead and didn't have to have it removed. This was done by professionals at the boatyard. May be a viable option for you, I don't know.

I hope you got a deal (free) on the boat, and please be careful that you do things right such that you aren't creating a hazard through th erebuild. By the sounds of it, you have other boats, and maybe rebuilding is a hobby for you, if so, it would be interesting to track the rebirth of this boat as you work on it. Please keep us posted!

Edited by - on

Rich P
1st Mate

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USA
77 Posts

Response Posted - 12/03/2008 : 12:54:57

Boat was a freebee (see my "New to me" post). Upon further inspection this will not be hard to do at all. Worst part of the bulkhead will be finding a suitable replacement board to use as I would like to keep the wood grain look. I started to take the old board's screws out and then it dawned on me that others would like to see, so I snapped a few (bad) pics with my phone but plan on keeping a decent camera available for the rest of the project. Plan is to remove old board and trace the pattern onto a new piece of marine mahogany or teak plywood, but I have to get a thickness and go see what my lumbar yard can get me.

I do have other boats (36' Pacemaker, 15'Boston Whaler, Waverunner GP760, Sunfish) and grew up on the water. I just rebuilt a transom on a 17' Wellcraft and will be working on finishing that boat as well before spring.
I've also slavaged a '72 Triumph that I still take out once in a while.

Edited by - Rich P on 12/04/2008 15:43:03

pastmember
Master Marine Consultant

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2402 Posts

Response Posted - 12/04/2008 : 20:14:15

That bulkhead must be replaced.

Edited by - on

Ed Cassidy
Captain

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USA
365 Posts

Response Posted - 12/04/2008 : 20:56:14

Along with the Spitfire. I'll see if I can find it a new home if you like!

Edited by - on

Rich P
1st Mate

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USA
77 Posts

Response Posted - 12/05/2008 : 08:01:47

Old bulkhead is almost out. Most likely to be my Saturday project if the Mrs. dosen't have me doing Christmas lights. The Spit is nicely tucked away in the garage for winter and since that pic was taken has a nice chrome front bumper added.

Edited by - on

Steve Milby
Past Commodore

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USA
5908 Posts

Response Posted - 12/05/2008 : 08:10:07

From the looks of the Spitfire and the well organized shop, the C25 is in good hands!

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Rich P
1st Mate

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USA
77 Posts

Response Posted - 12/05/2008 : 08:52:32

The Spit was a basket case almost 10 years ago. Rotted floors and rockers, connecting rod through the side of the engine. I did everything except the paint job, but since then I have gotten better at painting by spraying my truck bodies (3 of them) every year. The Cat has a long way to go, but will be back in shape soon enough.

Edited by - on

crcalhoon
Captain

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USA
303 Posts

Response Posted - 12/05/2008 : 09:43:55

I have replaced all four bulkheads on my C25, but judging from your posts, you certainly don't need any of my advice. For any others considering it, I will say that it is not as much of a job as you might think. (he said, just before the hull collapsed)

Edited by - on

Rich P
1st Mate

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USA
77 Posts

Response Posted - 12/05/2008 : 11:32:07

What did you use for material?

Edited by - on

Happy D
Admiral

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921 Posts

Response Posted - 12/05/2008 : 11:58:59

I used 1/2" teak faced plywood. It was gastly expensive. I removed the bulkhead and removed the piping on the edge of the board. I re-installed the bulkhead and used it as a pattern and spiled? the new bulkhead. The fit was much better. Some of the original gap was 3/4" or better.
I used 1/8" beige piping to fill the gap and it looks great.

Edited by - on

Rich P
1st Mate

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USA
77 Posts

Response Posted - 12/05/2008 : 12:30:38

Local lumber yard or did you order it from somewhere?

Edited by - on

Happy D
Admiral

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921 Posts

Response Posted - 12/05/2008 : 12:53:09

I was traveling through Detroit and bought it at Public Lumber in Detroit. I researched this for a long time before it all came together.

Edited by - on

crcalhoon
Captain

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USA
303 Posts

Response Posted - 12/06/2008 : 11:34:39

I didn't feel that I could afford teak ply here in Arkansas. It costs as much to ship it in as it does to buy it. I used 1/2 birch ply, sealed the edges with epoxy, stained and varnished. Not a great solution, but it worked for me and the whole job was less than $100.00
Two sheets of birch ply, some epoxy resin a little vinyl for the trim. I had the stain and varnish on hand. Mine fit a lot better than Catalina's did.

Edited by - on

Dave5041
Former Mainsheet Editor

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USA
3758 Posts

Response Posted - 12/06/2008 : 12:23:54

I used birch faced ply and epoxy sealing on my previous boat. It's really stunning with a teak stain.

Edited by - on

Rich P
1st Mate

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USA
77 Posts

Response Posted - 12/06/2008 : 16:07:40

According to my brother in law (roofing and siding contractor) getting teak plywood from the local lumber yard should be no problem, just might take a few days.

Edited by - on

Rich P
1st Mate

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USA
77 Posts

Response Posted - 12/10/2008 : 09:17:58

New wood is ordered. 4x8 1/2" marine plywood, teak face on two sides- $175. Should be here around the end of next week.

Edited by - on

Happy D
Admiral

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921 Posts

Response Posted - 12/10/2008 : 17:21:21

I ordered a piece from my favorite lumber yard. The teak pattern was horrible! I sent it back. Make sure you look at both sides very carefully before you take it home.

Edited by - on

txbigfoot
Navigator

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USA
194 Posts

Response Posted - 12/11/2008 : 00:13:19

I have a parts boat with a good bulhead and good interior. I would be happy to sell the entire boat to you so you can use it for parts. the boat is in austin Texas. i can deliver as far as oklahoma.
Dan

Edited by - on

Rich P
1st Mate

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USA
77 Posts

Response Posted - 12/11/2008 : 10:25:47

I did see your parting post, but TX is way too far for me (NY). I kept an eye on it since I am looking for the rear pulpit but someone got it first. I will probably just fabricate one since I still have the remants of the old one and some stainless tubing kicking around. How many circuits are on your DC electric panel?

Edited by - on

Happy D
Admiral

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921 Posts

Response Posted - 12/12/2008 : 07:35:01

Rich P.
A little tip. When drilling for the chain plates, what I did was drill only the bottom hole first, located from the old bulkhead. Drill the other three after the bulkhead is in place. That makes the holes alignment with the deck opening perfect.
Obviously use a brad point drill and drill from both sides.

Edited by - on

Rich P
1st Mate

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USA
77 Posts

Response Posted - 12/12/2008 : 10:55:33

My plan was to refit the bulkhead with the screws all around the perimiter. I was then going to set the chain plate so the top was going out of the deck the same ammount that the other chain plate is and then start drilling the new holes. Getting the exact hole spot from the old bulkhead would not be all that easy.

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