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Catalina/Capri 25/250 Sailor's Forums

General Sailing Forum

Bulkhead repair / replacement

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Dan86
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130 Posts

Initially Posted - 02/22/2004 : 22:35:52

I have finally decided that I need to either repair or replace the starbord, aft bulkhead, where the upper shroud mounts due to some water damage allowed to occur from the PO. The area has some rot affecting the top anchor bolt and I have two options as I see it. I can use some of the penetrating epoxy products and try to reinforce the area (cosmetically it does not look bad from the cabin) or I can repair by adding some backing in the area of the sink, or replace the bulkhead altogether. Any input and pros and cons would be great. Thanks dan 86 TR/FK.

Also, where do you find a bulkhead if needed, i did not see it in the catalina direct list of parts.

Edited by - Dan86 on 02/22/2004 22:37:11

Leon Sisson
Master Marine Consultant

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USA
1893 Posts

Response Posted - 02/22/2004 : 23:37:01

Dan86,<blockquote id="quote"><font size="1" face="Verdana, Arial, Helvetica" id="quote">quote:<hr height="1" noshade id="quote"><i>originally posted by Dan86:</i>

...starbord, aft bulkhead, where the upper shroud mounts ... water damage ... rot affecting the top [upper chainplate] anchor bolt ..<hr height="1" noshade id="quote"></blockquote id="quote"></font id="quote">If you haven't already done so, poke around with an ice pick or similar to determine the size, shape, and location of the rotted area. Do this stabbing on the opposite side of the bulkhead from the SS chainplate. It might help to pull that chainplate out first so you can also poke around in its footprint. The idea being to limit your stab wounds to areas that would be covered either by the chainplate itself, or by a larger backing plate installed on the opposite face of the original bulkhead to reinforce the damaged area.

The size of the damage and the degree of rot will likely determine what your repair options are. I think you're on the right track, considering penetrating epoxy, a patch maybe combined with some sort of backing plate, or worst case, replacing the bulhead.

If there is a badly weakened area larger than about a deck of cards, consider cutting out a rectangular or diamond shaped hole that includes about all the serious damage, and fitting a patch of new plywood there. If you're concerned about retaining original cosmetic appearances (and real masochistic), you could look around the boat for a hidden section of that same plywood, cut the patch out of that, and then patch the hidden spot with new marine plywood. You would still likely need a backing plate over the chainplate patch. This could be more plywood, aluminum or SS plate, or epoxy fiberglass sheet (probably precast). Regardless of what the backing plate is made of, after it's trimmed to size and drilled, it would be bonded in place with maybe a few screws too.

As for getting a new bulkhead, check with the Catalina Yachts factory parts department. They may tell you you're on your own, but it can't hurt to ask. Also check with that guy down in Texas who has been parting out one or more C-25s. See if he has or can find what you need. If you can't find (or afford) a factory bulkhead, then remove the old one and use it as a template to cut out a new one. You can either hunt down, order, ship, and pay a fortune for genuine teak veneer plywood, or use marine grade plywood and paint or laminate it yourself. But let's hope it doesn't come to that.

Let us know more about the size, shape, and location of the damage.

-- Leon Sisson

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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.