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Catalina/Capri 25/250 Sailor's Forums

General Sailing Forum

Cutting a slot in the boom

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Tom Potter
Master Marine Consultant

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USA
1913 Posts

Initially Posted - 04/24/2005 : 12:11:00

I'm planning to install a topping lift on Knotty Cat, I've looked at several ways to do it and of course I decided on the hardest. The plan is to cut a slot on the starboard side of the boom about 1/2" wide and a couple inches long (just like the one on the port side used for the outhaul). I plan I run the topping lift line through the rear of the boom to the front and back out the new slot and to a clam cleat. My understanding the newer models already have the slot on the starboard side for this.

My question is, what's a good tool to cut the aluminum with?

1997 250 TR WK (sold)
1984 O'Day 28 (sold)
1979 SISU 22
Bath, NC.

Edited by - on

dlucier
Master Marine Consultant

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Virgin Islands (United Kingdom)
7583 Posts

Response Posted - 04/24/2005 : 12:44:46

Although I've never cut a slot in my boom, if I needed a 1/2" slot, I'd first drill a 1/2" hole on each end of the slot then complete the cut with a saber saw with a metal cutting blade. After cutting the slot, clean up the edges with a file.

Another technique would be to use a smaller drill bit to make holes at the four corners of the slot then connect the dots with a saw.

Whatever technique you use, remember to ease all corners to prevent cracking.

Edited by - dlucier on 04/24/2005 12:46:12

Leon Sisson
Master Marine Consultant

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USA
1893 Posts

Response Posted - 04/24/2005 : 12:59:05

tompotter,

I've cut slots in a couple of booms. Here's the procedure that works for me.

Measure carefully. Draw the proposed slot on the boom with pencil. Stop for the day and think about it some more. Measure again, even carefully. You might want to protect the immediately surrounding surface of the boom from scratches with a couple layers of amasking tape. Drill holes in the boom to form the ends of the slot. (In your example 1/2" slot = 1/2" drill.) Cut the sides of the slot with a fine tooth blade in a jigsaw. Finish up the rough cut slot using a metal cutting burr in a Dremel or similar die grinder, hand files, sandpaper, etc.

If you're feeling particularly fanatical, you could install bullseye fairleads inside and outside the boom a bit past the ends of the slot. Just getting the edges of the slot good and smooth is probably less work.

-- Leon Sisson

Oops! Didn't mean to duplicate Don's advice; I didn't see it when I started my response. He just types faster!

Edited by - Leon Sisson on 04/24/2005 13:02:40

Arlyn Stewart
Master Marine Consultant

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USA
2980 Posts

Response Posted - 04/26/2005 : 16:58:48

Tom,

The slot for the topping lift was the first mod I made on my 250. Your right... there were no provisions on the earlier 250s for the topping lift other than extra sheaves available in the boom. I simply copied what was done for the outhaul and later Catalina started doing the same.

I can no longer remember how I made the slot... but the outhaul does work very well at that location.