Cape Dory 27 pulpit repair deck recore and teak repair

[Clint Rinehart]

So I am a relatively new cape dory owner having bought Glissade last year from another Cape Dory Board member. As such, I am still learning and dealing with the repairs associated with my learning. In this case, I damaged and bent the Pulpit when returning to the dock earlier this spring. This required a little tube bending and welding to repair. As it bent, one of the feet of the pulpit damaged the fiberglass deck. I cut out this area and found wet core.

[Clint Rinehart]

I have exposed the wet core on the deck under the foot. Digging it out, it seems the main source of the moisture was from the cleats. The plywood underneath was soaked and disintegrating. I decided to replace the plywood square reinforcement under the cleats with many layers of fiberglass. I recored with some high density polyurethane closed cell foam and west systems epoxy. I would not recommend doing this job while the boat is in the water on a busy lake in 90degree temperatures.

[Clint Rinehart]

Meanwhile, we have had a stormy spring here in Atlanta, and one of my deck lines broke, causing the stern of the boat to bang against the dock. More fiberglass repair and woodwork!

[Clint Rinehart]

While I am at it, I might as well replace my leaking hatch glass and re-seal it. All I have left for this repair is to touch up some of the topside paint, apply my kiwigrip antiskid, and replace my deck fitting for the anchor chain exit (hawsehole?) Oh, and also rewiring of the nav lights.

[tjr818]

As a 27 owner let me welcome you and say thanks for sharing photos of your work. That seems like a huge task, congrats for getting that done while on the water. Did you replace the top piece of decking or did you create your own new layer? I do not want to criticize, but rather to caution you, the port aft dock line in photo IMG_0692.JPG shows some fraying and should be replaced, otherwise your new repair might get redamaged

[Clint Rinehart]

It seems that I dropped a different tool into the lake on every other weekend. I replaced the top decking with new fiberglass. 1 layer of matt and 2 layers of bidirectional. The dock lines that broke to cause the damage were smaller diameter. I will certainly be replacing dock lines and snubbers at an increased rate from now on after this ordeal, as well as padding on the areas of the dock that could come into contact with the boat in the case of a future failure.

[tjr818]

It seems that I dropped a different tool into the lake on every other weekend. . . .

We used to have a diver that would come by every month to retrieve dropped items - I really miss him, I have a whole set of battens and a few tools on the bottom below Slainte.

[Clint Rinehart]

I've been making an ROV for that. It is a project in itself.

[Frenchy]

Wow! - I'm awed by all the work you did while still on the water! The hatch glass looks beautiful. Another
way to retrieve metal tools is with a big magnet- harbor freight sells one and so do some marine suppliers.
The marina I used to haul out at always had one handy because the workmen were always dropping tools
too. - See, you don't have to be an amateur to lose tools. Good luck - Jean

[hilbert]

Working with resin/fiberglass in direct sunlight, on the water is like having one arm tied behind your back. Very impressive.

I also need to replace a hatch lens.
I was wondering where you purchased the new polycarbonate, the dimensions and what adhesive/sealant you used?
Thanks, Jonathan

[Clint Rinehart]

I ordered the polycarb from mcmaster carr. Part number 87115K124. I got a 2'x2' sheet of grey scratch resistant .2" thick that I cut down on a table saw to the exact size, and I then cut the corner radiuses on the bandsaw. I stuck it down with butyl tape, and then caulked the joint with some expensive boat silicone adhesive for the pupose sold by westmarine.

[John Stone]

Great work and a great attitude Clint. I expect we are going to hear more from you. Love the ROV.

I dropped a socket in the water last December. Too stubborn and too Irish to let it go. All I had was a shorty wetsuit. Had my sister come down to tend a safety line. Put on my mask and fins. Water was so damn cold I almost lost my breath. But I got that socket back. I was shivering on the dock dripping wet, ginning like a fool, and so proud of myself. An old salt—a retired Navy submariner Chief Bosun Mate—with a West Sail 32 looked at me, shook his head and said, “John, the first rule of boating is “Shit falls into the water! Get over it.”” LOL. Pretty smart guy.

At least you’re smart enough to make a machine to recover your tools.

[OceanSailor]

Wow big project and great result! Have you decided to reapply gelcoat?

[Clint Rinehart]

I'm not doing gelcoat this time. Primer, topside paint, and kiwigrip.