Air Compressor Rehab

My porter Cable C2005 150 PSI pancake air compressor valve stopped holding air while we finished up the Keel repairs.   I thought I was going to have to buy a new compressor, but YouTube to the rescue!  All I had to do was replace the value.  You’re supposed to open this after every use so water doesn’t get left in the air tank and rust it from the inside out.  I’m pretty good about doing it, but I guess the valves just go bad no matter what you do.

Replacing was pretty simple.  Locate the value, identify the compressor type, and go to amazon and buy a new one.  I splurged for Prime membership for the free shipping and use the heck out of it.

Air compressor valve

Air compressor valve

Tools needed are a replacement value, a 9/16 wrench, and some plumber’s tape.

tools needed

tools needed

Take of the old value

Take of the old value

compare old and new valves

compare old and new valves

That hook like thing on the old valve is a gasket that is past its lifetime.  Notice the new valve doesn’t have one.  I think it’s inside the valve.

Wrap plumber’s tape around the new valve threads a couple of times and screw it in, tighten it and test.  Done!

Job complete!

Job complete!

 

Is it worth it to fix the sunfish?

After receiving the unwelcome and discouraging guidance from that well known west coast Catalina supplier that I should take the Catalina 22 to a boat yard to finish the keel weldment repair, I redirected my attention to the Sunfish I’ve carried around with me for the last 2 years.

This is what it looked like when I first saw it:

Being given a sunfish

First look at the Sunfish

Here is what it looked like recently when I took out the splash guard grommets:

Recent sunfish photo

Recent sunfish photo

I’ve been wavering back and forth about just repainting it as is, or removing the beat up trim first. It will cost around $100 to get replacement trim for it, so it’s not exactly a trivial matter. I decided to take the trim off carefully and see if I could maybe polish up the trim and reuse it. This was fine for the bow and starboard trim.  The rivets don’t actually go all the way through the trim.  They just go through the top layer and into the fiberglass.  First you drill out the center…

drill out the rivet

drill out the rivet

just…enough.. to get the top to pop off.

rivet drill out complete

rivet drill out complete

Starting at the end of the trim piece, I just pried the trim over the remaining rivet post and off it came.  Easy as pie.  It’s interesting to see that the original paint job was done before the trim was added.  Very nice Bicentennial stripe there – this is a 1976 Sunfish and the stripes match the old (rotted and useless but with pretty red white and blue colors) sail.

Old Bicentennial stripe

Old Bicentennial stripe

Once I got to the third and last piece on the port side it was a different story.  I broke a drill bit…. and another drill bit.  I noticed these rivets seemed to be bigger than the other ones.

Broke a drill bit

Broke a drill bit

And I was having trouble getting the trim off once the rivet was off.  It. Just. Would. Not. Come. Off!!!  Then I could see why.  It had been caulked in this spot.  Hmmmm….

It just won't come off!

looks like some kind of caulk

Then I saw that these rivets were all the way through the trim.  This boat has already been through a repair job.  I finally got  the last piece of trim off, but unfortunately, it was in about 6 pieces.  So much for reusing the trim.

Not reusing this trim for sure

Not reusing this trim for sure

And this lovely site in the picture below was revealed.  The top has separated from the bottom.
Here you can see there is caulk in the join that might be sealing it – and might not.

hull split

hull split

A little further aft it looks like the hull is fully separated.  In addition, there are quite a few spots around the hull flange that are in pretty bad shape.  Here is the view from the bottom.  Almost everywhere that had a large rivet (about 3 feet on the port aft quarter) it looks like this.

other damage

other damage

So.  I’m looking at:

$100 full trim replacement
$100 fiberglass supplies (epoxy, catalyst, cloth, rollers, etc.)
$100 complete sand, paint and gelcoat,
$250 replacement hardware and running gear,
$350 new sail.  (May be able to repair the one I have, but I doubt it)

At least $900 .  I just looked on craigslist and I can get a great looking one for $650.

What to do?

I’m discouraged.  I’m not making progress on either of my boat projects.  I don’t think I’m a very good CapnRehab.

New home for the Cat 22 Keel

You may remember when I got the Catalina 22 replacement keel last year.  I threw some wheels on a shipping pallet and put the keel on the pallet.   Pretty fancy huh?

wheels repaired and pallet re-loaded

Fancy Pallet stand for Catalina 22 keel

Recently, I bought the video on repairing a Catalina 22 keel from Catalina Direct.  In it they show the steps for reconditioning the keel.  This weekend I took the first step down that path and put the keel in a vertical stand so it can be worked on.

The first thing I did was use my engine hoist to pick the keel up.  Well, actually I picked up one end.  It’s pretty long and the hoist isn’t big enough to lift it completely.  Remember this this thing weighs between 500 and 600 pounds, so moving it around isn’t trivial.

Lifting the keel

Lifting the keel

Then I took the wheels from the pallet along with some 2×4 scraps left over from “the project that must not be named”, and made a new support frame.  It was a simple matter of lowering the keel onto the new support and Wa-La, the keel is ready.

Keel on new stand - ready for work

Keel on new stand – ready for work

Wow, that keel needs a lot of work.  A nice thing about this stand is that it takes up way less room than the pallet.

You’ll notice a sunfish on sawhorses in the background of the first picture.  I also did a bit of work there.   More on that next time.

 

Less than helpful

Let me bring you up to speed on the Keel repair.

My buddy “Curtis in Alaska” scared me.  He finished his keel weldment repair and went sailing.  He told me he had a pinhole leak that over the course of a four hour sail let in about half a gallon of water.  Yikes!  After I do this repair I want zero water in infinite amount of time!  So while I was gung-ho to go ahead and finish, that made me put the brakes on real quick.

As a side note, he’s pulled his boat out of the water for the winter.  HOLY SMOKES, he told me that in August!  Curtis buddy, you know I respect you, but living where it is that cold makes you a bit crazy in my book!

I decided to call a well known (really well known) Catalina parts supplier on the west coast and get some advice before I pulled out the gloves and started slathering on epoxy and fiberglass.  The salesman I reached at first was very helpful and suggested I buy a west systems fiberglass kit they sell.  He also said to be sure and use epoxy and not vinyl.  Then he referred me to tech support.

They should be called tech non-support.   He said it’s simple fiber glassing, nothing special if you know what you’re doing.  He said Curtis’ patch must be leaking because he left air bubbles in it for the water to get through.  He wasn’t even helpful enough to mention what the salesman had said about using epoxy.

After explaining my experience level (almost none-except for the bit where I helped my buddy Phil fix blisters on his keel)

(Hi Phil, by the way, I’ve lost almost all my Florida phone numbers when my phone died – please give me a call or email me so I can look you up next time I go down to FL)

the guy told me the job was too big for me and I should take it to a yard and let them do it!   Argh!!!!!   Made me so mad.  I don’t know why but I get so bent out of shape when I’m fixing a problem that I don’t quite know how to do and someone says I should call an expert.    Maybe I’m just too cheap.

but I figure anything someone else can do I can do – eventually.

Anyway, they were no help so I’m on my own. I may have to practice on the sunfish first.

Catalina 22 moved to the garage – work to begin soon

Big doings here at the Rehabitat.  The Catalina 22 has a moved.

I wanted to get her inside the garage so I could open her up and start working without worrying about the weather.  This is what I faced on Saturday morning.

Future home of the Catalina 22

Future home of the Catalina 22

After a bunch of moving, re-stacking, organizing, shoving and cramming I got a hole opened up.

Cleared away

Cleared away

Don’t EVEN ask what the rest of the garage looks like now!  Here is a side view so you can see the before/after shot.

Another view of future Catalina work area.

Another view of future Catalina work area.

Yes, that is Big Red the riding lawnmower with the hood up.  He sat too long with a busted starter and now that I’ve put a new starter on, the carb is not letting any gas get to the spark plug.  I’ve been doing a lot of work on him, but since it isn’t boat related I’ve held off posting about it.

With some masterful backing up by yours truly, the Catalina is sitting pretty in her new home.

Catalina waiting to be worked on

Catalina waiting to be worked on

Yes, that’s about 4 inches to spare!  She’s touching the back wall and I had to lower the front end all the way to the floor so I could close the garage door.

The whole trailer couldn’t fit, so I had to completely pull out the trailer extension.  That took a bunch of “Fabulous Blaster”,  a magnetic penetrating lubricant.  It also took quite a few whacks with a sledge hammer.

Trailer extension removed to fit trailer in garage.

Trailer extension removed to fit trailer in garage.

The extension is the black bar sitting on the ground to the left of the trailer.

Yes, it’s exciting times here at the rehabitat.  I’ve already started working on the keel fix, but that’s a story for another day.

 

Catalina 22 keel replacement – purchase

Bought the keel yesterday.  It was a small adventure on an absolutely beautiful sunny day.  I got to meet a great guy and he says he’ll guide me if I need help getting through the keel rehab.  Here are a couple of links he suggested.

 

http://groups.yahoo.com/group/catalina22/

 

http://www.catalinadirect.com/forums/fr_topics.cfm?forum_id=98

I have to be able to move the keel around myself, including unloading it once I got home.  I decided to put wheels on the keel pallet and that should let me roll it down the ramp.  So I took everything I could think of that I might need.  Here I have beefed up the pallet with 2×4’s and then added wheels.

pallet mobility enhancement

pallet mobility enhancement

Then he loaded the pallet into Mrs. CapnRehab’s horse trailer.

loading keel

loading keel

A short drive to his house to pick up some parts, and then head for home and unload.  Here is how it looks at the rehabitat.  Yes Charlotte, I got the blue one 🙂

keel in the trailer

keel in the trailer

The best laid plans…  Things didn’t go quite as planned while unloading.  Hit a bump and the wheels stopped but the keel didn’t.  Yanked the nails right out.

wheels fell off

wheels fell off

ALL the wheels came off.   I muscled it over to a temporary pallet so I could repair the wheels.  I’m glad somebody invented the lever.

moving to temp pallet

moving to temp pallet

 

wheels repaired and pallet re-loaded

wheels repaired and pallet re-loaded

It turns out it isn’t that hard to move the keel around one side at a time.  I can’t even pick up one end, but I can slide it over – that’s all I needed.

Soon to be joined….  stay tuned.

Catalina 22 and keel

Catalina 22 and keel

(OK, not so soon, I have a lot of projects going on right now)

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We don’t need no stinkin keel!

Catalina 22 Keel Repair.

Well, maybe we do.  This is the reason the previous owner gave me the boat.  We have a serious lack of keel:

Keel slot - no keel

Keel slot – no keel

In all these pictures, the bow of the boat is toward the top of the picture.

Here is a close up of the bolts.  Or should I say where the bolts used to be.  They look like they’ve been sheared off.

Sheared Off Keel Bolts

Sheared Off Keel Bolts

Here is the same spot, but at a slight angle.

Sheared off keel bolts at an angle

Sheared off keel bolts at an angle

To give you some idea of the mess this is, I went looking for a picture of one in good condition and found this Catalina 22 / Fleet 20 Portland Oregon blog entry

Hangar Bolt Weldments

Hangar Bolt Weldments

Here is a picture looking up into the keel cavity.  I think that thing sticking out of the side may be a “stay down”  bolt, but not sure.

Keel cavity

Keel cavity

Wow, it looks like I have a LONG way to go to get this boat in the water!  Unfortunately about the only required skill I currently possess is patience and the inability to recognize when a job is too big for me.