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Corroded pylons/fill with epoxy and fiber for a solid core?
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Author:  ALEXSAILS [ Tue Jun 05, 2007 7:33 am ]
Post subject:  Corroded pylons/fill with epoxy and fiber for a solid core?
Hi, The top part of my H16 pylons are corroded (where they enter the corner casting) and the bolt hole has elongated making the connection sloppy on all four corners.

This is the idea:
Fill the inside of the pylon with expanding foam leaving about 8 inches on top to be filled with a mixture of epoxy resin and chopped glass (sort of like SEACAST) http://transomrepair.com/zk/
This will make a solid core of fiberglass inside the pylon on the top section, from where it exits the deck and flush on top of the pylon. Re-drill for the 1/2" bolt and wala! We have a solid pylon that wont corrode because its fiberglass core and a new and tight bolt hole to hold the corner casting secure.

cast the vent tube inside the pylon as the foam is being poured....

I considered what another member did, weld another extrusion inside the pylon and re-drill for the bolt hole. But this will eventualy corrode again, and the bolt hole will eventualy elongate again.

Added weight is not a problem as I wont be racing the cat. Besides this will only add about 2 1/2 lbs per hull...not a big deal to me.

any opinions??
Author:  ALEXSAILS [ Tue Jun 12, 2007 2:49 pm ]
Post subject: 
anyone?
Author:  MBounds [ Tue Jun 12, 2007 4:49 pm ]
Post subject: 
You asked the same question 6 months ago:

http://www.hobiecat.com/community/viewtopic.php?t=5229&start=17

You were expecting different answers? :?
Author:  ALEXSAILS [ Wed Jun 13, 2007 7:33 am ]
Post subject: 
oopppsss thinking of this stuff every day makes me forget the stuff I think about every day...

thanks!
Author:  John Eaton [ Wed Jun 13, 2007 7:57 am ]
Post subject: 
ALEXSAILS wrote:
oopppsss thinking of this stuff every day makes me forget the stuff I think about every day...

thanks!


AHA! Another human online :wink:
Author:  Brig Bill [ Fri Jun 15, 2007 1:37 pm ]
Post subject: 
Alex
I assume you are referring to my repair welding the new extrusion inside the old pylon. True they will eventually erode and the holes possibly elongate. But I now have double the thickness of the pylon for the bolt to elongate. The holes in the old pylons were welded and ground flush and the redrilled holes are a tight fit. If you look at the photos you can see cracks and thinning at the top of the old pylons. A bead around the top helped build that up. The boat is back on the beach, is tight and sails great. If I can go another 12 years without any trouble I will be happy.

Bill
Author:  antxvilla [ Thu Jul 05, 2007 11:37 am ]
Post subject: 
Alex:

I did the same thing as bill about a year ago, I´ve sailed the boat 4-6 times/month since then in different wind & wave conditions 0-25 kn(pitch pole included) and the boat is still much stiffer than it was before the repair.

Hope it helps
Author:  ALEXSAILS [ Fri Jul 06, 2007 10:36 am ]
Post subject: 
I got to install and weld some alum sleeves inside each pylon. 1/8" thick and 5" tall.
I drilled about ten 1/2" holes around each sleeve before pounding them inside the pylons an welding. The weld came out super nice and even filled the bolt holes with alum before gringing down, they are solid and about four times the original thickness!!
These holes are so the epoxy/fiber cast will grab on to the pylon like hell.

I received the epoxy/1/4" chopped fiber/two part foam and epoxy pigment last week and will get to work on filling them this weekend.
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