I have got the AI back in my workshop and have started addressing a few of the problems that have cropped up.
The first item is the worn / elongated holes where the pins go in that locate the aka to the crossbars. I am fabricating some phosphor bronze top hat bushes to go in the crossbar and the aka. The plan is to have the brims of the top hats facing each other. This will provide a nice bearing surface and I will ream the hole for the pin, so it is a nice play free snug fit. At the moment there is approximately 1" of travel at the ama due to the sloppy fit. I am also going to lengthen the elastic a little, at the moment it is so tight it is putting a strong side loading on the pin, that isn't helping. I will post some pics once I have the bushes in place.
When I unbolted the crossbars, I was surprised by the amount of corrosion going on with the bolts and under the mounts. I would have thought it would be worth using a sealant when assembling to prevent the salt water from getting under there. I will seal mine when I re assemble.
I noticed that there are a couple of fairly beefy tabs that are on the back of the mast well that sit directly under the crossbar. They are drilled, but not attached to anything. Anyone know what they are for and should they be attached?
The plastic insert that locates the end of the lockout strut has come loose. The plastic shear bolt is a sloppy fit and unable to force the tube to clamp up on the fitting, resulting in about 1/8" end float occurring. I will replace the fitting, but am not keen on the plastic bolts. I may fit a stainless steel bolt instead through the tube that will force the tube to clamp up on the fitting and fit a shear bolt on the hinge itself. Still thinking on this.
I pulled the rudder pin out after the mauling it took in the Mud bank incident a couple of weeks back. As you can see in the pictures it is a bit mangled. I will upgrade to one of the new grey pins instead. I still haven't broken a pin yet, so do not feel the need to strengthen that yet. I will see how the grey pin does.
My last gripe today is the locking hatches. As you can see in the photo, with it locked it still sits unevenly. I don't believe the O ring type seal is able to work in this application and it dumps water in when you open it that has collected around the seal. Anyone know of a better set up that will fit?
I will keep you informed of progress.