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Catalina/Capri 25/250 Sailor's Forums

Catalina 25 Specific Forum

Port Bulkhead Replacement

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jesse camp
1st Mate

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USA
84 Posts

Initially Posted - 06/22/2005 : 10:00:44

After looking at trying to use Git Rot without much sucess, I decided to replace the port bulkhead on my 87 25. The PO allowed a leak to continue without repair and the resulting rot damaged the bulkhead and made the area around the chain plates weak. I removed
the bulkhead carefully, not to break or incure further damage. After
removing all fasteners, approximately 25-30 different screws and bolts, I purchased a sheet of 1/2 inch teak marine plywood, which is about $135.00 per 4x8 sheet. The dimensions of the bulkhead are about
48 x 54 inches. I used the old bulkhead as a template to cut out
a duplicate. I traced out the shape and used painting tape to prevent
splitting of the laminate. I used a scroll saw to cut out the piece. I then sanded the edges and fit back into
the boat to check to make sure it fit, which it did. Again using the
template I used an ice pick to mark all the drillholes and marked them. I later matched the template hole sizes to the new bulkhead.
Use a piece of wood under the bulkhead when drilling to prevent splitting on the otherside. I then varnished and polyurethaned the
piece. I made up a length of nauragahide to go between bulkhead and
the boat similar to original trim. The piece fit very tight but most of the drillholes matched up very close, and I was able to
put back together. Looks good, and I dont have to worry about chainplate failure.Thanks for all the advise.

After Thought: You will have to remove the piece over the Swing Keel
chest (if applicable) and document what fastener goes where when dissasembling because there are different length screws. Also the piece between the main bulkhead and veeberth bulkhead and clothes rack bar will have to be removed as well. Do not throw away any scraps of teak, the small pieces can be used to match the varnish. I ended up using two colors to match,a mahogany and pecan stain from Home Depot and then used polyurethane. I notice that colors vary from boat to boat so matching is tough.

Good winds
Jesse

Jesse Camp

Edited by - jesse camp on 06/22/2005 13:58:29

Frank Hopper
Past Commodore

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Pitcairn Island
6776 Posts

Response Posted - 06/22/2005 : 10:33:10

Hi Jesse,
I am the Mainsheet Tech-Editor. I would appreciate using this in the next Mainsheet. Did you take any pictures? Any more details? Where did you buy the wood? Did you try to get a replacement from Catalina Yachts?

Edited by - on

Leon Sisson
Master Marine Consultant

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USA
1893 Posts

Response Posted - 06/22/2005 : 10:37:33

Great job Jesse!!! Excellent technique. Although you may not have been real happy about the price of the plywood, look on the bright side. You now have enough left over to do lots of repairs and/or upgrades to the interior. Or, if it matches the original Catalina interior closely, you could try to peddle it in our Swap Meet section to others who need to add or replace smaller pieces of C-25 interior wood. Where did you find/order the teak veneer plywood?

-- Leon Sisson

Edited by - on

jesse camp
1st Mate

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USA
84 Posts

Response Posted - 06/22/2005 : 10:52:49

Sorry, I did not take photos. Of course, it now looks the same as the original. I tried Catalina direct and also spoke with engineering at Catalina. I even spoke with the original woodworking supplier to Catalina. They dont know what template I need because they build or built so many for Catalina. I found a supplier of marine plywood called World Panel Products 1750 #1 Australian Ave Riviera Beach, Florida 33404 561-840-0500 web www.worldpanel.com
I brought along my old bulkhead and here are the specs they matched
to the original piece

Burmese Teak Marine Plywood Exterior
2440 x 1220 x 12 mm 2 sides

I think the only way to do this is to use your original bulkhead as a template, Catalina more or less told me they did not have a drawing
I could use (so much for mass production). This is a first time effort for me and after looking at a couple of other repairs from other boats on various websites I decided to "git er done". I never did find anyone else how has done this on a Cat 25. We are lucky we do not have to glass in the bulkhead like on other boats.
Let me know if you have any other questions.

Good Winds,
Jesse Camp
87 25 SK/SR
Orlando, Fl

Edited by - on

Frank Hopper
Past Commodore

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Pitcairn Island
6776 Posts

Response Posted - 06/22/2005 : 10:57:30

Thanks for additional info, I have a new friend that needs to do this.

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Dan86
Navigator

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130 Posts

Response Posted - 06/22/2005 : 22:41:39

Did the same repair on the starbord bulkhead using marine plywoood. Used the old as a template. Had to "recreate" some of the lines due to rot from a PO neglect of the chainplates. Worked well, Stained and looks very similar to the original. During this time, I removed the sink in the head and have more storage. By the way, sealed all the edges with epoxy to prevent any wicking of any moisture into the panel, and used the over drilling and epoxy method to strengthen my bolt sites. Leon is a great advisor on these projects as are many others. Dan

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Notice: The advice given on this site is based upon individual or quoted experience, yours may differ.
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.