Repair to coachroof
Date: April 30, 1999
From: Kim Bell belljk@bigpond.com
Hello, I am writing on behalf of my parents living in Queensland Australia. They have lived on a house boat in France for many years and have now decided to live on an Endeavour 40 in Australia. They have asked me to contact you on an urgent problem they have with their boat. They were very glad to hear you existed as they have been trying to find advice from someone who knows the Endeavour boats well.
They have purchased a damaged boat. They have a 75cm split at the foot of the mast. They repair yard require proffessional instruction as to method of repair because some strengthening will probably be involved. They would like to know of any accepted method of hull repair of modifications required. Do you know of anyone with similar problems with a repair.
Having looked at your site a I am sure my parents would love to join your forum.
Thank you for your time
very hopeful on behalf of Ray & Wendy Jackson
(my name is Kim Bell)
Date: May 3, 1999
From: Rob Jones jones@viaccess.net
If someone can communicate with me and email pictures showing the crack and damaged area I can advise them of a structural solution. My background is in boatbuilding ,mold and tool building and damaged vessel repair, (hurricane) in many instances.
Rob Jones S/V August Moon E 40
St Croix USVI
Date: May 3, 1999
From: Tom Powers TomPowers@sunnuclear.com
I have not had a similar problem with my E40 but, I do know of someone who did on their E42.
They had been in a severe storm and jibed, the jibe cracked the deck at the partner. The crack let in water which was absorbed by the foam above the head liner. The headline began to sag until he punctured it to drain the water.
The repair was done at a large marina in Cape Canaveral, Florida. The repairs were completed in the water, with full rig in place.
First, the headliner and foam was removed. This exposed plywood sheeting that was attached under the decking. The plywood was cut out in large area around the mast, which included the ceiling in the forward head. Then the underside of the decking was cut by use of a circular saw set to a depth so as to not penetrate through to the deck upper surface.
The E42 decking was constructed with a plywood core. First the gel was placed in the mold. Then the glass cloth and resin, followed by small (5 to 6 inch square) squares of plywood impregnated with resin. Then the final interior glass was laid. The core is then made up of small plywood squares which is designed to reduce water wicking through the deck core.
The interior glass layer and plywood squares were chiseled out with an air chisel. This left just the upper deck glass layer and gel coat.
The upper layer of the decking was repaired from below and the gel coat repaired on the outside. Then the marina made up full sheets of decking core with the interior glass layer already attached. They left raw glass cloth around the perimeter of the sheets to assist is bonding around the edges. They painted resin on the sheets and lifted them into place and held them there with timbers. They then glassed the loose cloth to the existing interior overhead.
New plywood was replaced, along with new foam and new headliner.
The decking did not appear to have any additional bracing or strengthening in the area around the mast, and the marina repair did not add anything in this area either.
I know this is a lot of information in a brief note. If I can be of further assistance, please feel free to contact me directly.
Tom Powers
E40 - PINBALL
Date: May 3, 1999
From: Roger Wright roger4th@swbell.net
More information is needed to be of any assistance.
Your e-mail indicates a 75 cm split at the foot of the mast. Is the mast split? Is the deck split where the mast goes through the deck (Known as the "partners") Is it in the hull at the mast step in the bilge? Which direction is the split? How wide is the split? Does anyone know what caused the split?
I am in the boat repair business and would like to offer some help, but more info is needed. My suggestion at this point is to find a marine surveyor (I suppose there are marine surveyor's is Australia). I would also suggest finding a boat yard that knows something about fiberglass repair. This is not rocket science and any good boatyard should be able to do a reasonable hull repair (the 40 hull is all fiberglass) or a reasonable deck repair. The area around the partners is a cored deck and a repair should be reasonable to repair. Not cheap, but reasonable depending on the extent of damage. While at 75 cm split can be seen, delamination of fiberglass or cored material can go far beyond the visible. The only way to find out is grind away until good material is found and affect a repair from that point. Again, this is something any good boatyard in any country should be able to do.
Best of luck.
Date: May 9, 1999
From: Dennis & Barbara Rings Moxsun@aol.com
Kim, I think I may be of some help in this area.
The way that Endeavor layed up the keel and mast step in our 43' Endeavor is as follows, they set the keel in place (lead) , then placed a 8 '' channel down and bolted the keel to it, this was the basis for the resin core and formed the hull up from there, at that point they welded two additional struts up from the channel in the top of the keel and placed another 8'' channel over the top of the "keel channel "and welded the top plate or channel that forms the basis and structure for the mast step. Sounds like you have a problem in this area.
I think because you have stated that the boat was damaged, it may have taken a real hard grounding or maybe water penetration has weaken this area and additional damage has occurred from the damage that had been done to the boat. I am not sure with out looking at the problem or knowing more about the particulars of the damage that has occurred to the boat if this is the problem that you are having, I hope that it is some help, We took ours apart because of a weak mast step and the more I got into it the more I understood how the boat was built.
Our fix was relatively easy once I figured out the problem, I was able to create a way to fix it, reinforce it and make it as strong as original if not stronger, of course there is a story with the fix but I won't bother with that right now, If you would like more information about my fix or have more information to work with I might be able to better help, you can e-mail us if you have any more questions
Date: September 20, 1999
From: Rick Diz diz@gannon.edu
Dear Paul:
I just happened to read an entry from you on the Endeavour owners discussion history about E32s.
I am considering purchasing a 1977 E32. A boat survey identified a possible serious structural issue regarding the mast step and compression post. The cabin roof is slightly depressed on one side of the compression post, and the teak trim next to it is cracked. There is no apparent movement of the compression post down into the keel, but the boat is in the water and was not pulled out for the survey.
Does this sound like a major issue to you? It really doesn't look like much to me, but then I am a novice at this sort of thing.
Thanks in advance for your advice.
Date: September 20, 1999
From: Paul Uhl endvr32@endeavourowners.com
Ric,
I'd be concerned, but then again I haven't seen it, read the survey, or talked to the surveyor. Several things however raise my concern.
1) That the survey was done in the water indicates to me that you may not have received a proper survey. A proper survey should be out of the water, should be a lengthy written report with photos, etc. For example, if the boat is in the water there is no way to tell if the boat has blisters, or if the rudder is in good shape, etc. How did you find the surveyor and how much did you pay. The last survey I had done cost me about $500 and the boat was already out of the water.
2) What did the surveyor say about this issue. They sometimes indicate items to cover their behinds but with something like this they should go into more detail. Compression in the cabin roof can be more than cosmetic as it is part of the integral design. The strength of the hull and how the loads are distributed from the downward pressure generated by the mast is a critical design factor. Get as much information about it as possible and don't be afraid to press the surveyor. Also ask him how much it might cost to fix it.
3) Does there appear to be any softening of the core in the area. The depression you mentioned could be a result of several things. Was the mast dropped on the deck next to the mast step causing the coach roof to fracture? Is it from an over tightened rig? Has water migrated through the gel coat into the core? All these things can be fixed--at a cost.
Endeavour sailboats were over built glass with mat roving in the hull and glass with (I believe) plywood in the deck and areas needing reinforcement. This was typical for the period and boats today are generally built lighter but stiffer. The point I'm trying to make is that it takes a lot to damage the boat. I'm not an expert in this area but I've seen Endeavours wash up on shore with minor damage to the gel coat and other boats totaled. They're tough boats.
All I can tell you is research this very thoroughly. It could be a big issue and it could be expensive--but if it is, it most likely can be fixed. It comes down to how much the boat costs, how much it costs to fix it, and if you're willing to go through it.
