[C320-list] Crack Between Hull and Keel

[Dave Hupe]

Update......

I have been in communication with Catalina Yachts in Florida (wrapping up with Gerry Douglas who has been involved with the 320s since their inception/hull #1). The following is their recommended repair to hopefully prevent this problem from recurring:
1) haul the boat again letting the keel hang to keep the rear crack open fully during the repair
2) clean out the interface all around the keel at least 2 inches outward on the hull and keel (to eliminate mixed repair materials from past fairings)
3) use thickened epoxy to fill in again (use West Systems epoxy - thickened as needed)
4) fiberglass at least several layers all around the interface with 1808 material (Available data on the internet says this material contains 18oz fiberglass woven at 90 degrees. On the backside a layer of 3/4oz fiberglass mat is also attached. This material reportedly offers strength in various directions and is great for many projects. Thickness is .048") 
5) Add fiberglass layers extending about 6 inches outward on both the hull and keel .... to form a fillet (like the newer 320s that have the deeper bilge) which should sufficiently strengthen the area so that such cracking/separation doesn't repeat from seasonal lifting/putting on cradle
 
I spoke with Gerry about adding an additional aft keel bolt (say adding an 11th keel bolt/lag screw in the aft bilge area to support/reinforce the rear part?). This is not recommended by Catalina. 

Wish me luck!

Dave Hupe
1994 Hull #32
Holland, MI