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Catalina/Capri 25/250 Sailor's Forums

Catalina 25 Specific Forum

broken pop-top latch

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mountainsailor101
Deckhand

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USA
12 Posts

Initially Posted - 04/11/2009 : 09:59:27

One of our pop-top latch connection points (the fiberglass portion)was broken when the top came down too fast one time w/o the latches being in the proper position. Anyone ever have to deal with that repair?

Edited by - on

Voyager
Master Marine Consultant

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USA
5378 Posts

Response Posted - 04/11/2009 : 10:23:08

Mtn -- this is a tricky repair, since the latch is a critical stress point and a poor design. You may be able to cut out a larger portion of the broken area and fill it using fiberglass and resin to reconstruct. West Marine's "advice section" shows how to make repairs.

Another approach is to move both the port and starboard latches further aft or forward on both sides, to connect into more solid stuff. Of course you'd have to patch the holes and broken area. Marine Tex?

What I would not do is try to epoxy the broken pieces back together or try to rebuild the broken section with Marine Tex. This would not provide enough strength and would break again next time it came down.

Also, some folks have purchased gas-filled pistons to prevent the poptop coming down hard like that. Catalina Direct should have them.

Edited by - on

mountainsailor101
Deckhand

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USA
12 Posts

Response Posted - 04/11/2009 : 11:09:18

Thanks Bruce... yeah, it doesn't look like there's any easy way to go... and I have seen the gas-filled @ Catalina Direct. Since there's still about 2-3 feet of ice on the lake I guess I have plenty of time to consider my options.

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Dave Bristle
Master Marine Consultant

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Djibouti
10005 Posts

Response Posted - 04/11/2009 : 11:50:34

Another good trick to prevent this in the future is to attach some small "pole clips" next to the hanging bolts so you can snap them up against the top, out of the way for raising and lowering.

CD's gas struts are apparently very helpful--effectively reducing the weight by about half. (I only know this from others' comments.) As I understand it, to install, you need to have the mast down so you can "charge" the struts by tipping the poptop further forward. With the mast up, there isn't an easy way to get a full initial charge.

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Dave5041
Former Mainsheet Editor

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USA
3758 Posts

Response Posted - 04/11/2009 : 11:54:26

Pole clips! Another great, simple idea and cheap solution to offset annual dues.

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pastmember
Master Marine Consultant

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2402 Posts

Response Posted - 04/11/2009 : 15:26:25

Catalina added a second set in the later production. The pole clips are from Catalina Direct.

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Voyager
Master Marine Consultant

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USA
5378 Posts

Response Posted - 04/11/2009 : 17:27:50

Frank --
That's a nice addition, it should make the poptop a little more secure. I might go for two pair, one pair forward and another pair aft.

Of course, that'll be after I complete the bottom painting, finish the electrical panel, put on the stern pulpit, clean & wax the hull and wash the sails.

Well, there's always next year!

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jaclasch
Navigator

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USA
104 Posts

Response Posted - 04/11/2009 : 23:02:09

There is an easier way to install the gas struts from Catalina Direct that doesn’t require taking the mast down or compressing the gas pistons. Basically you are using the pop top itself to compress the struts in the last step.

• As shown in the manual from Catalina Direct, locate and mark the positions to mount the front brackets.
• Install the front brackets as indicated.
• It is important to have the bracket ball-connectors exactly the right distance from each other. Use a piece of flat wood molding to make a positioning jig. Mark two spots exactly 10.75 in. apart on the strip and drill two holes slightly smaller than the pivot balls on the brackets. A 3/8” bit works fine.
• Use this jig to position and mark the rear brackets (with the pop top down).
• Install the rear brackets. For best results drill one hole for each bracket and fasten with a single bolt. Then check spacing again. If you are a little off it is still easy to correct.
• With top up and locked against mast, run a piece of rope through the top mounts of the aft pop top stanchions and form into a bridle that is then pulled up aft of the hatch cover and hooked to your main halyard.
• Run main halyard around a winch and tighten up so halyard will not allow rear of pop top to drop.
• Remove pivot screws at the bottom of the aft pop-top stanchions.
• Unlock pop top from mast.
• Now one person slowly raises rear of pop top with the winch while second person watches from below until struts line up with mounts and snaps them into place.
• Lower top slowly until rear stanchion holes line up and replace big pivot screws.
• Slacken and remove bridle and begin using top.

Edited by - jaclasch on 04/11/2009 23:02:53

Dave Bristle
Master Marine Consultant

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Djibouti
10005 Posts

Response Posted - 04/11/2009 : 23:46:00

James: Good info!

Bruce: You can save that for post-launch.

Frank: What's the barrel-bolt on the cabin bulkhead for??

Edit: Must be the traditional interior table... Duh!

Edited by - Dave Bristle on 04/11/2009 23:47:17

Prospector
Master Marine Consultant

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Canada
3159 Posts

Response Posted - 04/12/2009 : 14:11:11

I put tee struts on this past fall, and if I (All thumbs) can do it, then you can. As for having to remove the mast, there are ways around it. as I was glad to find out. Do some searches.

Our Dogs always get in the way when we open/close either th epop-top or forward Hatch. A tip OI found that I plan to implement is to attach velcro around the circumference of the knobs, and then the opposite piece where the knob would swing to the ceiling. This would hold the knobs out of th eway, but not mean major surgery.

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The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.