[C320-list] Removing the Maxwell 500

[Scott Thompson]

These links to documents I put on the Association website a long time 
ago might be helpful:

Exploded parts view: http://www.catalina320.com/filemgmt/index.php?id=112
Manual: http://www.catalina320.com/filemgmt/index.php?id=113

The former is for the VC500 model (no chain gypsy) and the latter is for 
the VW500 model, which includes a chain gypsy, but my understanding is 
that the drum assembly is the same on both models. The VW500 model has a 
longer shaft and a few extra parts. Based on your description I suspect 
you have the VC500.

I believe that the drum should NOT turn when rotated with a pipe wrench 
because it is keyed to the shaft and shaft rotation is more or less 
impossible because of the use of a worm gear in the transmission. But 
rotating it is not required for removal. Rather you need to move it off 
the shaft without rotating it, i.e. by moving it parallel to the shaft 
and internal key. In other words, it should just slide off the shaft. If 
the drum won't move parallel to the shaft there could be internal 
corrosion or sand preventing it from sliding on the shaft.

What I would do is insert a lever (try a large screwdriver at first) 
between the drum and mounting plate and try to pry the drum away from 
the mounting plate. If that fails try levering in more than one place, 
or get a bigger lever. When it moves, it will probably give all at once, 
so arrange for some protection of the gelcoat in case it goes flying off 
the shaft with gusto. Also avoid using the fiberglass itself as a 
fulcrum. You want the intense point-loading to be entirely metal to metal.

I don't think it is possible to remove the windlass in one piece, or to 
remove it without first removing the drum, even with a willingness to do 
damage to the windlass. The problem is that the motor / transmission is 
on one side of the bulkhead but is bolted to the mounting plate on the 
other side, and the bolts are hidden by the drum. You need to remove the 
drum, then the bolts holding the motor, then the motor itself (which 
requires access to the rear, obtained by removing the plywood panel from 
the front of the V-berth and then lying on your back looking upward), 
and only then the mounting plate.

Been there.

Scott Thompson
Surprise, #653

On 5/16/2013 10:27 PM, Gene Helfman wrote:
> We've decided to replace our non-functional Maxwell 500 (1997 c320) with a
> newer, larger model with a chainwheel, the Maxwell VW10.  I'm now trying to
> get the old 500 out and am stuck.  Does anyone know how to remove the rope
> drum?  I've taken off the outer cap, screw, and washer and can't figure out
> what to do next.  It doesn't help that the drum appears to be frozen in
> place and can't be rotated, even with a pipe wrench.  I'm not afraid of
> breaking things if necessary, although if I can get the whole thing off the
> boat in one piece I'd be happy to offer it up to anyone gratis for spare
> parts.
>
> gene
>
> *Satori*, #398
>