Cutlass bearing replacement and bottom job report

[Carl Jones]

I just got finished replacing my cutlass bearing and shaft, doing a bottom job, and compounding and waxing the hull on Spanish Eyes, my beloved 1983 CD30. There have been numerous questions about cutlass bearing jobs, including my own, on this board, so I thought I would report my experience to possibly help others.
I am a pretty fair mechanic, but had never seen or done this procedure before, so I hired a man to do it for me this first time. His charge was a very reasonable $150. I am glad I did. It was very difficult to get out. First, he pulled the shaft, which was easy, then he located the set screw for the cutlass and removed it. The CD manual shows four set screws, but Spanish Eyes only had one, so don't believe everything you read in the manual. There was about 3/4 inch of cutlass protruding from the shaft log and he tried to break it lose with a pipe wrench, but it only collapsed. Finally he had to cut it lengthwise with a reciprocating saw. Since I don't have one of these, I probably would have been messing with it all day. After cutting a slot in it, he was able to bend it, turn it some with a wrench, and drive a screw driver between the cutlass and the shaft log to break lose the epoxy that was holding it. Finally, he put a pair of vice grips on it and tapped on them with a hammer to ease it out. The whole job took him about two hours. I would have probably still been there.
The other problem was getting the bolts out of the coupler. They weren't badly rusted, but very difficult anyway. I had to get help for that and then I had to cut the head off one and take it out with a pair of vice grips. It took about three hours to get out the three bolts.
My mechanic ran his pocket knife across the threads on the shaft and it put flats on them, indicating damage from electrolysis. There was other electrolysis damage evident in the cutlass area. The shaft was 16 years old. We replaced it with a brand new Aquamet 19 stainless steel shaft, a much better material than bronze. I can't complain after 16 years, but this makes another strong case for changing your zincs. I change mine 3 times a year. A local machinist made the shaft for $168.
A strange phenomenon occured to my hull. No one in the yard has ever seen this before and I promise I wasn't drinking! When I bought Spanish Eyes six years ago the surveyor (the top rated one in our area) pointed out some blisters at the turn of the bilge, that were about half the size of your hand. He said they weren't enough to worry about, but should be watched. I did a bottom job later that year and they were still there. I used Interlux Ultrakote paint. When I did my bottom job now, five years later, they were no where to be found!! There is not a blister anywhere on my hull! I have never heard of blisters going away before, has anyone else?
One last point: this boat is very economical to maintain. My total expenses were $1342. When you spread this out over five years it comes out to $268 a year. That's not bad for one of the very best rides you can get on water! Kudos to Cape Dory!
Carl Jones
CD30 Spanish Eyes



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