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PostPosted: Wed Jul 23, 2014 8:09 pm 
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Joined: Sat Oct 29, 2011 4:27 pm
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Location: Central Oregon
Cracked my right rear corner casting. Scored a replacement of unknown vintage. All was good till I went to put the pylon bolt in. Hole is not even close. Guess these are just drilled as the boat is assembled rather than jigged up?
So do I go ahead and re-drill through the pylon? Drill a whole new hole through casting and pylon? Tig up the hole in the pylon and re-drill?
Any other options I am not seeing??
FYI...the boat was making all kinds of noise and seemed to be a lil more flexy than I remembered before I noticed the crack. We were sailing in big wind double trapped for days on end with it cracked I think lol.

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PostPosted: Thu Jul 24, 2014 2:56 am 
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Options that I can think of....

1) Buy a new corner casting and be done with it.
2) Drill through the pylon to match the hole in your replacement casting and then epoxy and bolt the corner casting in place.
3) Drill a new bolt hole through the casting and pylon above the existing hole(s).
4) Fill and re-drill the hole in the pylon. There was a hotline article not to long ago that described how to do this with brazing material that works using a propane torch.

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PostPosted: Thu Jul 24, 2014 3:24 am 
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Are new corner castings un drilled?
Curious how #1 could fix issue?

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PostPosted: Thu Jul 24, 2014 6:43 am 
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hobiesrock wrote:
Are new corner castings un drilled?
Curious how #1 could fix issue?


Good point. That was my assumption based on the fact that that the hole locations are different from one casting to another. You would definitely want to verify from a dealer that the pylon is undrilled before forking out the $$$ for one though.

By the way, the pylon repair article was in the Mar/Apr 2010 Hotline issue.

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PostPosted: Thu Jul 24, 2014 10:11 am 
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Checked that article out...interesting. I want to pick up some of that aluminum rod they were using just to have around.
I just priced new castings $200 a pop. OUCH. Not going that route. Also noted that every pic of new castings I found online had the holes drilled for the pylon bolts already. And called up a dealer and asked and as far as they knew they come pre-drilled.
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So I think I am going to just wallow out the holes enough to get a bolt through. And sail it. If its flexy I will think about gluing it but that sounds like a real pain if I should ever need to get the frame apart again. Some of the joints were hard enough without glue!

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PostPosted: Thu Jul 24, 2014 11:31 am 
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Having replaced my hulls i delt with the same issue, I just drilled overlapping holes in the plylons to allow the bolts to pass through. As far as epoxing the frame and hulls togeather, night a day difference between unglued. it was so much easier to fly a hull and tack and lost alot less speed in waves and chop. I have also dissasembled a boat that had been epoxied togeather, and it was easy to get apart, a few taps with a mallot and while applying heat with a blowtorch (the epoxy i used melts at 140 degrees F) and it poped right off. I have actualy had more trouble taking appart and old boat for the first time than i did taking apart a boat that was epoxied togeather. i used west Systems with 404 high density filler


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