It's been a while since I posted. I'll start with the traveler. The existing Harken traveler was mounted on a wood base that extended it over the recessed area that the original stock J/30 traveler fit in. This had the problem of the control lines sometimes getting caught in the space between the wood base and the forward and aft edges of the recessed area. The area also collected dirt, grape, cheese, crackers, whatever.
The old wooden mount was removed. I measured the recessed traveler area and determined that the void could be filled using a 2 x 3. I ended up using two 1 x 3 Red Oak boards. These were planed to fit and the bottom edge rounded to account for the rounded edges in the recessed area.
I covered the top surface of one piece with fiberglass tape using neat epoxy. This is merely to seal the wood surface
that will be exposed, prior to covering with Gelcoat.
I made an aluminum template to capture the position of the existing holes that mounted the traveler. This was used to drill the holes in the new wooden base so they would align precisely with the existing holes on the deck. You can see in the photo below an alinement check of the bolt holes on the template. I brought the template home and drilled the wooden pieces on my work bench.
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| Template Trial Fit |
All of the pieces laid out on deck can be seen in the photo below. Ultimately the aluminum template will be used inside to spread the load between the nuts and washers that mount the traveler.
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| All the pieces |
The photo below shows the trial fit of the wood pieces. You can also see where I recored the stbd side. This will be covered with Gelcoat at the same time when I Gelcoat the traveler mount.
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| Trial Fit Wood Pieces |
The chainplates were removed and cleaned up with a scraper and wire brush. This provides access to the holes in the deck so they could be drilled out and epoxy isolated. The port side was dry on the deck, but the stbd side required that core be dug out, dried with a heat gun, and injected with thickened epoxy.
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| Chainplate |
Below is a picture of the stbd chainplate hole that has been epoxy isolated and sprayed with Gelcoat.
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| Chainplate Deck Opening |
The area below deck where the chainplates bolted to the bulkhead was cleaned up. The stb side had no problem even though there was wet core in the deck above.
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| Stbd Bulkhead |
The port side below showed signs of stress cracks and the upper part of the bulkhead compresses when the chainplate fasteners were tightened. This will be put on the work list for next year.
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| Port Bulkhead Cracked |
Some additional epoxy isolation on deck was done in the cockpit area. Each of the locker hinge mounts was over-drilled and epoxy filled. The holes were drilled and tapped for a 10-24 that will replace the stainless "wood screws" that were previously into the core.
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| Deck Locker Screw Holes Epoxy Isolated |
New teak handrails were mounted. I taped of the deck and around the teak so it was easier to build a seal using flexible caulk. You can see the teak bungs inserted before being cut off and sanded.
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| New Teak Handrails |
