[C320-list] New Boat knocking noise

[Jerry Brown]

Hi Bill

I suggest that your dealer contact Gerry Douglas.  My dealer has still 
failed to find a resolution and has been in detailed discussions with Gerry 
Douglas.  As of yesterday Catalina was air freighting parts to Toronto to 
replace the driveshaft and coupling.  My dealer had planned to use the shaft 
and coupling from a stock 320 he had at a satellite location, when the boat 
arrived (on water) it was found that the shaft and coupling were even more 
heavily marked than mine so they were not used.  I do not know the hull 
number of that boat.  My dealer is now talking about "honing" glass out of 
the tunnel as it looks like their was either insufficient clearance at build 
or more likely there is an alignment problem built into the hull.  I am very 
uncomfortable about the idea of shaving away fibreglass to create a straight 
path, despite assurances that there is "plenty of material there so it will 
not create a structural problem".  A lot of effort goes into protecting the 
hull fibreglass from water intrusion such as Interprotect so cutting into 
the glass would seem to me to create an obvious point where osmosis can 
start, yet the dealer has no solution as to how he would effectively protect 
the glass once "honed" given the location and small spaces.  That will be a 
discussion for today as I may not be understanding something.

It sounds like there is pretty fundamental production quality issue which 
may be spread across a number of boats.

I would welcome comments from other list members about the idea of "honing" 
the tunnel by cutting into the gel coat/glass and the possible implications 
on the future life of the boat.

Regards

Jerry Brown
Indigo #1137

----- Original Message ----- 
From: "Barb & Bob Uhlman" <uhlman at sbcglobal.net>
To: <C320-List at Catalina320.com>; <jbrown03 at simpatico.ca>
Sent: Friday, June 27, 2008 7:31 AM
Subject: Re: [C320-list] New Boat knocking noise


Jerry,
I save this thread of emails in case I needed to look at it later.  We do.
We took possession (#1158) two days ago and it has the same knock as you
described.  It was particularly loud in the lazerette.  Our dealer had our
marina pull the boat yesterday looking for something caught in the prop.
Everything was clean.  It will be moved to the marina where the dealer has a
working relationship on Monday.  This morning I will continue looking at
these messages for the answer.  If you already have the answer, please email
me with it.  Thanks.

Barb Uhlman
Whisper, #1158
Carlyle Lake, IL


-----Original Message-----
From: c320-list-bounces at lists.catalina320.com
[mailto:c320-list-bounces at lists.catalina320.com] On Behalf Of Jerry Brown
Sent: Saturday, June 21, 2008 9:05 AM
To: C320-List at Catalina320.com
Subject: Re: [C320-list] New Boat knocking noise

Thanks Bob.  I believe that someone on the list has Gerry Douglas e mail
address.  If anyone does, could they forward it (and his phone number if
possible) to me please.  I think I should comment that I have known the
dealer for a long time and I know he is as frustrated as I am.  I do not
want to paint him in colours as black as you suggest.  He is trying to work
this out in his own way.  My colleague in the next office purchased as new
Beneteau 10R this year and his dealer problem list is the same if not worse
than mine.  This is simply not a professional business, as for example the
car business has had to become, at least in our part of the world.
Incidentally my first thought was that the mounting bolts had been left
loose after commissioning.  Unfortunately that has been shown not to be the
issue by the subsequent realignments.  I am wondering about the security of
the bonding of the mounts to the hull.  I am planning to look for stress
cracks or similar when I go to the boat today to take off our personal
items.

All other ideas or theories gratefully received...........

Regards

Jerry Brown
#1137 Indigo
----- Original Message ----- 
From: "Robert Seastream" <robert.seastream at comcast.net>
To: <C320-List at Catalina320.com>
Sent: Saturday, June 21, 2008 9:32 AM
Subject: Re: [C320-list] New Boat knocking noise


> It almost sounds like your engine mounts are extremely loose.  It also
> sounds like your dealer just wants to close the deal and get rid of  you
> and the boat.
> I'd call Gerry Douglas at Catalina Yachts, tell him briefly of this
> (including the dealership name & info), and tell him you'd like to  send
> him a followup email with more details.  I'd also make it known  to all
> parties that I'm considering washing my hands of this dealer  and boat (if

> possible), taking my business elsewhere.
>
> I feel for you; you simply want to go sailing, and time's running  out.
> However, with the sort of money involved, this dealers' attitude  and
> approach is hideous.
>
> Bob Seastream
> Intuition # 906
>
>
> On Jun 21, 2008, at 7:28 AM, Jerry Brown wrote:
>
>> Suggestions Please
>>
>> Our new 320 is sitting at the dealer.  From the day of commissioning
>> there has been a loud knocking sound from the stern whenever the  boat is

>> motored over about 2300 revs - we were told it would "settle  down".  In
>> two hours of motoring from the dealer premises to our  club the engine
>> moved on the mounts sufficiently that it jammed the  engine cover which
>> was free when we left (I checked the oil before  leaving).
>>
>> Initially the dealer "blamed" the Kiwi Prop that I supplied, and he
>> installed.  He realigned the engine and told me to take the prop off  and

>> reinstall the standard two blader.  While still tied to the dock  we
>> tried the realigned engine (still fitted with the Kiwi Prop) as I  was
>> reluctant to move the boat for fear of doing more damage.  The  dealer
>> also dove under the boat to check that the prop was not  fouled and that
>> the blades were free. In that test the engine was  moving around
>> sufficiently to open up the stuffing box under load.   The dealer then
>> thought that the initial motoring and engine  movement might have bent
>> the propshaft.  The dealer then arranged to  have the boat moved (with
>> minimal motoring) back to his premises.   The Kiwi Prop was removed and
>> the shaft and coupling sent to a  machine shop for checking.  With the
>> boat out of the water it was  clear that the shaft was not aligned.
>>
>> The machine shop confirmed that the shaft and coupling are true.   The
>> standard prop was then installed, the engine again realigned  (the
>> mechanic is getting lots of practice) and the boat put back in  the water

>> with assurances that all would now be good.  The opposite  is true.  At
>> 2300 revs the noise is more persistent and louder than  with the Kiwi
>> Prop.  A subsequent test by the mechanics with the  engine covers off
>> lead them to say that, at the point where the  noise starts, the motor
>> can be seen to "move" sideways visually.   Another symptom is that when
>> the engine is throttled back,  a  relatively low frequency vibration
>> passes through the hull which can  be easily felt at the wheel.  The boat

>> almost seems to be "shaking  it's hips"  There are no abnormal engine
>> noises etc, no black smoke  or any other signs of engine problems.  It is

>> smooth at idle and  when revved in neutral.
>>
>> Having confirmed that this is not a Kiwi Prop problem (i.e. my  problem
>> from the dealers perspective) the dealers' next suggestion  is that
>> possibly the wrong engine mounting rubber blocks were  installed from
>> new.  That seems a possibility, but a pretty remote  one.  I would
>> welcome other theories as our season is rapidly  disappearing.
>>
>> Jerry Brown
>> #1137 Indigo