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Question: how to replace corner casting - step by step
http://www.hobie.com/au/en/forums/viewtopic.php?f=20&t=15562		 Page 1 of 1
Author:  Paris [ Thu Oct 01, 2009 6:28 am ]
Post subject:  Question: how to replace corner casting - step by step
Hi all,

My port/aft corner casting is cracked. I have the replacement. But I have no idea how to replace it.

If someone on the list knows, can you possibly run me through step-by-step? I really need the "for dummies" version - what tool to use, how to use it, for each step, etc. etc.

I'm pretty sure this will involve removing and replacing the tramp, so if anyone has a guide on how to best string up the tramp (including which knots to use, etc.) that would be really useful too.

-Paris.
Author:  MBounds [ Thu Oct 01, 2009 12:00 pm ]
Post subject:  Re: Question: how to replace corner casting - step by step
No need to take the tramp off. Just loosen it.

You'll need a 3/4" crescent wrench, a 3/4" socket w/ratchet, a cold chisel, a hammer, a 3/16" punch (an old #2 Phillips head screwdriver will work), good rivet tool, a rubber mallet or dead-blow hammer and a drill w/ 3/16" and 1/2" bits.

It's best to do this with the boat on the ground (grass or sand) and relatively level.

  • Remove the rudders, or at least the tiller crossbar.
  • Loosen the tramp.
  • Remove the tramp bolts with the 3/4" tools.
  • Using the cold chisel/hammer, knock the heads off the old casting's rivets, then drive the tails into the casting/extrusion with the punch.
  • Loosen the frame up on the pylons enough that you can get the one corner completely off. No need to remove the entire frame - you just want the one corner off. This might require some persuasion (rubber mallet). NEVER HIT A GOOD CASTING WITH A METAL HAMMER.
  • Slide the casting off the sidebar, then the rear crossbar. This might require some persuasion (hammer).
  • Tilt the boat up on its side just enough so that the old rivet tails inside the rear crossbar will come out the open end (otherwise they will rattle around forever).
  • Slide the new casting on the rear crossbar, then on to the sidebar. Make sure it's seated well on the rear crossbar.
  • Seat all four castings down on the pylons.
  • Re-install the pylon bolts.
  • The pylon bolt hole in the new casting will probably not line up exactly with the old hole in the pylon. Use the 1/2" drill to clean it up so the bolt will go through.
  • Re-tighten the tramp. Try to level and square the boat - measure diagonally from bow tang to rudder pin and vice versa. Measurements should be equal.
  • Using the 3/16" drill, drill the rivet holes for the new casting into the rear crossbar using the casting as a template.
  • Insert and pull the rivets.
  • Reinstall the tiller crossbar
  • Done!
Author:  Paris [ Thu Oct 01, 2009 1:22 pm ]
Post subject:  Re: Question: how to replace corner casting - step by step
Thanks MBounds!
Author:  MBounds [ Thu Oct 01, 2009 3:00 pm ]
Post subject:  Re: Question: how to replace corner casting - step by step
Oh, yeah - one other thing - don't do this with the mast up.
Author:  Paris [ Thu Oct 01, 2009 4:08 pm ]
Post subject:  Re: Question: how to replace corner casting - step by step
MBounds wrote:
Oh, yeah - one other thing - don't do this with the mast up.

:lol:
Author:  mmadge [ Wed Oct 21, 2009 3:28 pm ]
Post subject:  Re: Question: how to replace corner casting - step by step
Hey Matt,when I had my front port corner casting replaced the hole for the pylon bolt did not line up.I was wondering by redrilling a new hole ,does this cause any loss in stiffness of the boat?
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