Beam Replacement Presentation

Please take the time to look at this Powerpoint presentation by Thomas Egan regarding the dreaded Beam Replacement. If you are using Google Chrome, right click on the link and select "Save Link As." If you are using Mozilla Firefox, right click on the link and select "Save Target As."

Cal40_Misirlou-Head-Refit_160625-01.pptx

The Dreaded Beam

Sinn Fein, 2014:

About ten years ago we replaced the beam in our 40. The yard price for a new beam was approaching about $3,000. Instead we hooked up with a Stainless steel dealer who not only provided the material but we was able to cut the ss to our specifications and shipped all for less than $600.00. A retired welding friend duplicated the beam in shining stainless steel for $500.00.

That was the easy part, the difficult part was removing the old beam and replacing it with our new one. To remove the beam we: removed the bottom of the standing locker common to the shower, removed the head, removed the lower part of the sink counter top, cut and removed the bottom four inches of both bulkheads, cut the top of the interior pan about two inches below the top. With all of those obstructions removed, and the beam detached from the turnbuckles and the bulkheades, we were able to remove the beam from the boat.

The replacement was a reversal of the removal process. Some woodwork was required to replace the cut bulkheads and considerable glass work to reattach the top portion of the interior pan that was removed. With the glass and woodwork completed, we reinstalled the lower section of the sink, the lower section of the standing locker and of course the head.

During Hurricane Sandy, lots of damage occurred on the starboard side of the boat, some of the glass work needed to be redone but the bulkheads remained in place with little or no damage.

This was a great winter project, and we reeped the benefits of being able to point higher and keep the rig tuned.

Good luck with your repairs,
Peter S. Rebovich

This is what I did to replace my cal 40 mast beam. First I cut the forward floor sections into 2 parts separated at the forward cabin/head bulkhead. I made the cut just aft of the bulkhead. This allows the forward floor liner to be moved forward slightly to give room for the head floor to come out. I had to remove some bad plywood forward of the bulkhead and this gave me some space to do that. The floor has to be able to come up slightly so a small amount of cabinet plywood needs to be removed and can be covered with a little trim piece later. There is a cleat on three sides of the floor that needs to be removed as well.

I did not have to do any trimming off the bottom of that bulkhead but had to remove the door. I cut the fibreglass with a 4 1/2 angle grinder with a thin cut off wheel and a sawsall with a medium tooth bimetal blade. The forward floor section is bonded to the hull on both sides on the bottom and with a fillet of glass cloth on the sides. Be careful to follow the contour of the hull so that you don’t cut into the hull or floor.

Now remove the front of the hanging locker the head door and small fore aft bulkhead the head and associated plumbing .then remove the entire head cabinet. It will be nice to make that all new . Now that that area is opened up cut the floor just forward of the bulkhead leaving enough material to feather out and bond to later. I was unable to remove the mast step fasteners so I cut around the whole step. This section of floor is also bonded on the bottom on the sides and also side fillets. Once separated the floor can be moved slightly forward and lifted at the forward end and removed. Now cut the tabbing holding the beam to the hull. On my boat it was one layer of thin fiberglass on each side forward and the same aft of the bulkhead. You will have to remove the settees .There are 2 small blocks that have 2 screws these come out first then you can tip up the whole works and take it out. There are 2 small 1x pieces that the settee slides on near the bulkhead that will need to be removed to get at the aft bonding on the beam. Now unbolt the beam and slide it forward tip it up an one side ( I think its head side up) now the nasty thing can exit the boat. Get help so you dont bang thins up and hurt your back. Rough guess on weight 175 lbs. The debate...galvanized vs stainless........ material cost approx. Stainless @ 1000 dollars steel galvanized @ 350 dollars. Fabrication cost variable. I chose steel partly because of cost and ease if fabrication( welding it myself). The old beam lasted 45 years and was poorly installed which contributed t its demise. I guess it’s a matter if choice and the size of your budget. There are some things you can do to prevent the rust out and they aren’t difficult.

Fin.....here’s the first part of my project I will continue in a couple of days and send the photos. Perhaps you can assemble it and pass it on to anyone who needs it. I have just about finished the project, a little cabinet work left. Second part to be sent is reassembly.

Cary Smith