Knees Broken (Part 1)

My worst fears have come true: the raised lumps on the deck that we discovered while refinishing are caused by the knees, which have separated from the hull and are rotating up and pushing on the deck inboard of the chainplates.  Three out of four knees have ~1/8″ to 1/4″ gaps at their bottom ends, and the tabbing towards the bottom is colored white, further indicating delamination from the hull.

We were intending to depart in January; I don’t see how that’s possible now with this job thrown into my lap at the last minute.  Karen and I just moved onto the boat, and I’m going to have to rip out the cabinets and do a massive fiberglass grinding and repair.

I removed the slats that hide the port forward lower; I chose to tackle this one first because it doesn’t require removing cabinets to access it.

I used plastic to tape off the entire area.  I wore a bunny suit, full facemask, and respirator.  I ground the fiberglass tabbing off until reaching clean, solid glass.  That part really sucks, the grinding.

Comments

6 responses to “Knees Broken (Part 1)”

  1. Ingrid & Andy

    Come on Matt, you’re on the last leg (no pun intended!)!!
    This is the last big job, anything else you can do along the way. We definitely understand your predicament, our fingers are crossed for you and Karen. Keep your chin up, you will smile back at it one day. 😉

  2. damn…..our mast step looks like it might be seriously rusted — fingers crossed, good luck with your rigging!

  3. mast step is totally corroded to the point that we pulled the mast today and tomorrow we remove whats left of the step then try and find someone to fabricate a new one — the things we wish we knew when we bought this boat 🙂

    and we’re in the boat yard which is costing a whole lot per day — ack, would you be interested in writing a sort of back and forth piece about the things you wish you’d known, the frusterations, etc. in trying to restore the boat, making this adventure, etc.?

  4. that sucks man, sorry to hear it. Make sure the new step has an inch thick piece of UHMW (ultra high molecular weight) polyethylene for the aluminum to sit on, so that the corrosion won’t repeat itself. You can get it from mcmaster. About the things I wish I had known, please ask anything, but my goodness it would take a book’s worth of details to tell you everything we learned, since so much of it is in the tiny details of how to do things most efficiently, even things as simple as cutting a piece of wood (in a corner with no space for a jigsaw, etc etc). Anything in particular you would like to discuss?

  5. Steve Johnson

    Had the same problem the step was not that bad looking at it with mast installed but when removed the corrosion was working from the inside. FKG in St. Maarten, refabricatted the step added the UHMW 1/4 inch off the bottom of mast and the 1/4 inch UHMW reinstalled the mast and all is well now.

    Chandara V40-171

  6. Barry

    Hi Mat. I just ran across your post on spartalk about your mast steps. (Quite the controversy). I’m getting ready to do a similarly message job to your knees on my passport 42: All my chainplates are glassed in and need to be dug out. While not as bad as your situation, still a stupid move. By the way, I’m just down the “road” from you (B42’ish). My boat is currently at kkmi while I finish up on my mast refit. Should be back an emerycove in a month or so.

    cheers!

    -barry

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