Installing boom extensions

[NS233_Bob_Neches (Bob Neches, Me Gusta, Nonsuch e26U #233)]

I could use advice on installing a Murray Cressman boom extension on my boat. Cressman is long gone, but there are still a few of these floating around.

This slips over the existing aft boom end and fastens by re-using 14 bolt holes on the original installation – six on each side, plus two aft. The aft holes are in the lower flange of the boom end, corresponding to the two bolts you’ll see in the middle of the picture above. They’re currently used for the padeye where the upper mainsheet block attaches. Two months of soaking the the fasteners with Liquid Wrench, plus a power impact driver, have almost freed the side bolts. That looks like it’s under control.

However, as you can see from these front and back pictures of the padeye, its fasteners appear to have been screwed into the aluminum rather than throughbolted. Forty years of corrosion has done its work. The padeye appears to be an imperfect fit, with something between it and the aluminum base. I can’t tell whether that was once an adapter plate that’s deteriorated, or corroded metal where the boom end met the padeye, or what.

With that background, my questions are:

1. How would that padeye originally have been fastened? What’s the best approach to removing it without damaging the boom end? In desperation, I could imagine running an angle grinder behind the padeye to cut it off, then grinding the area flat. After that, I’d try drilling differently placed holes through the stainless extension and the aluminum flange. Does that make sense, or is there no alternative to trying to drill out the existing seized screws?

   I’d like to retain the ability to reinstall a padeye in case I later want to remove the extension, but I’m wondering if that’s hopeless.

2. For the six holes on each side where the boom end piece is attached to the two boom tubes, the forwardmost top and bottom holes seem to have a single long throughbolt. The remaining four appear to be 3/4" long 1/4"x20 thread machine screws. Is there a reason for that vertical throughbolt, or could that be replaced with machine screws as well for ease of future disassembly/reassembly?

3. Since a large surface area of stainless extension and aluminum boom and casting will be in contact, I assume I should be worrying about how to provide insulation between them. What’s your advice about how best to do that?

Thanks,

– Bob

[NS233_Bob_Neches (Bob Neches, Me Gusta, Nonsuch e26U #233)]

Current score on Bob vs. bolts is Bob - 11, Bolts - 3. One throughbolt left and the two padeye screws.

Mike Quill told me that the padeye screws were peened after insertion so it looks like getting them off is going to be a challenge.

– Bob

[CaptFran1 (Fran Cichowski - N30U Southpaw #300 - Spicers, Noank CT)]

Hi,

Take anything I say with a bit of salt.

1. Have you tried some heat oh the two pad eye bolts?

2. If the objective is to save the pad eye

 a) Just center on the philips drive slot and drill until the head falls off
    Than just pull the undamaged pad eye off
        You might than be able to run the screw out
         OR
        You might be able to run it in if it goes thru
         OR
        If you are very lucky you might be able to just keep drilling
         AND
        Pull the remaining thread of the bolt out like a coil spring 
         Possibly save the threads with a Helicoil 

May I ask what is the purpose of this modification?

AND

Is this a class approved modification?

Corrosion Issue: I suspect something as simple as smearing the Stainless with silicone just prior to final assembly would last a lifetime.

Fran

[RonB (26U/214 Allegro Pender Harbour BC.)]

When I removed the extension none of the bolts were through bolts. They were all about 3/4” long. There was no isolation between the extension and the boom or cast piece. No corrosion either.

RonB.

[NS233_Bob_Neches (Bob Neches, Me Gusta, Nonsuch e26U #233)]

@RonB

When I removed the extension none of the bolts were through bolts.

Having removed one, I know that some on mine were. I don’t know why. Pretty sure the remaining one will come out eventually with heat + cold + Liquid Wrench + hammering.

@CaptFran1

Just center on the philips drive slot and drill until the head falls off…

That makes a huge amount of sense, Fran – I’m embarrassed not to have thought of that. Thanks!

@CaptFran1

May I ask what is the purpose of this modification?

AND

Is this a class approved modification?

The boom extension adds about 15” to the back of the boom, which brings the mainsheet blocks and lines further back. This makes them less likely to bonk the helmsperson or get them tangled in the lines as they move from one side to the other. People with biminis also like it for that reason. It also allows moving the connection to the topping lift back, which the roach of the sail from catching on it.

Since it doesn’t change the dimensions of the sail, I believe that it doesn’t violate the class rules. Every racer I’ve talked to with one seems either to have taken it off and sold it, or removes it when racing and puts it back on. The extra weight adds to the boom’s flattening effect, and I’m told this interferes with light air sailing.

In my case, I’m trying it out because the cut of my sail and the set-up of my choker doesn’t let me get enough out of the usual tricks for getting the mainsheet block an line as far back as I’d consider safe. (Putting a longer lashing on the sail clew and using the choker to bring the boom further aft is the usual answer. In my case, the cut of the sail puts the clew too low, so this doesn’t help me.)

– Bob

[Mirthin (Nick Hirst)]

From the class rules: #5 Spars and Rigging: Masts and wishbones may not be altered in any way from those installed by Hinterholler Yachts as standard equipment.

[NS233_Bob_Neches (Bob Neches, Me Gusta, Nonsuch e26U #233)]

I stand corrected.

I’m not a racer, but this is certainly a reason for trying to ensure the extension’s easy to install/uninstall.

– Bob

[Mirthin (Nick Hirst)]

I know you don’t race and have more interest in making your boat as comfortable and easy to sail as possible. Admirable goals. I believe that the racing tradition of the Nonusch is important to the class and enjoyment of those who like to race. The class progenitor Gordon Fisher was a racer and while he didn’t ask for the design to be for racing but for family and single-handed easy sailing, he did ask for performance and designer Mark Ellis delivered. Nonsuch enthusiasts organized a world championship early in the class history on Martha’s Vineyard in 1983 which set the start of a racing tradition. The Nonsuch in all its models is an easy boat to sail, a more difficult boat to sail well and like single-sailed dinghies is a quite difficult boat to race. It is a great idea to move the mainsheet away from superstructure at the stern, a feature that plagues other single-sailed boats (I can’t count the number of times I ditched my Laser when the sheet caught under the transom). The mainsheet block system is simple but I have wondered how to improve its performance and position. If extending the boom is a benefit then we can look at changing the class rules to allow it. I don’t know whether it will improve or inhibit performance but I suspect it will alter the shape of the sail and move the draft aft. I think that may lower performance on a reach and possibly upwind but others with more knowledge should comment.
Nick

Nicholas Hirst
nicholashirst@me.com

Mirthin N30U #513

RCYC

Regional Director Lake Ontario Nonsuch Association

Secretary of the International Nonsuch Association

[briancayer (Spirit~Wind N30U 419 Westbrook, Ct.)]

Bob
My thoughts exactly.
Brian

[Mirthin (Nick Hirst)]

I wrote that the extension would not fit with the class rules. Wrong! Rule #5 ‘Extensions to a wishbone to allow a sheet to clear sunshades or cockpit enclosures are allowed’. Should have read further into the rule. Sorry everyone.

[NS233_Bob_Neches (Bob Neches, Me Gusta, Nonsuch e26U #233)]

As I’ve been communicating with Mike Quill about all the challenges of freeing bolts to get ready for installing the extension, I’ve learned that he estimates that about 26-28 of the boats have this extension. (Or, at least, that’s how many have been in touch with him with questions about installation.)

– Bob

[briancayer (Spirit~Wind N30U 419 Westbrook, Ct.)]

This boom extension discussion interest me since I’m considering upgrading my old and worn dodger canopy combo with some kind of full inclosure on my 30U. I searched the back posts and found this reference from about 2017 ;

I bought mine from Murray Cressman cressy@sympatico.ca or (519) 893-3388. I have no idea if he is till around or not. I do know that he had them manufactured by someone so the manufacturer may still be around. Probably in the Kitchener, Ontario area.

Does anyone know of a source for these?

Brian Cayer

[briancayer (Spirit~Wind N30U 419 Westbrook, Ct.)]

No need to look further for Murray Cressman. He is in the hands of God.
Brian

Cressman, Murray:

It is with heavy hearts that we announce the sudden passing of Murray on Monday, June 25th, 2018, at his home in his 81st year.

Beloved common-law partner of Lyla Mavin for 13 years, ‎her sons Craig Mavin (Oakville), Bill Mavin (Kitchener), her daughter Wendy Mavin (Elmira), their spouses and all their children.

Devoted and loving DAD to his sons and daughter, Cameron Michael Cressman (Major) and his spouse, Yongmei (Jane) (Ottawa), Steven Murray Cressman, Brent Mitchell Cressman and Tanna Layne Cressman (all from the Halifax-Dartmouth area).

Predeceased by his parents Hilliard and Salome (née Meyer) Cressman and his older brother, Delton (Del) Cressman. Survived by his dear older sister, Wilma Strub, who played such an influential role in his childhood years.

A lifelong resident of both Kitchener and Breslau, Ontario, Murray was a descendant of the original handful of non-indigenous settlers (Mennonites) in the Waterloo County area, the Isaac S. Cressman branch of the Cressman family tree. He is an alumni of the Kitchener Collegiate Institute, back in those early long ago days when everyone in the then-small cities of K-W seemed to know each other.

Murray was employed for most his working life in the local petroleum industry. Starting as a truck driver in the early formative years of Schofield & deVries Ltd, he remained with the company in various positions including Vice-President Sales and Fleet Manager as it evolved through CANAM Oil Services, Breslube and (the old) Safety-Kleen company. Murray was a strong proponent of oil re-cycling long before it was championed by the “green industry”. And Murray was remembered as someone who could sell anything to anyone anytime.

Murray had many passions in his life - hurtling down the highway on his Matchless motorcycle, in James Dean-like leather jacket and peaked cap, heading off with his buddy, Larry Hodgins, spelunking (wild cave exploring) in Kentucky and Virginia. There was his love of exotic automobiles - a series of convertibles, Karman Ghia, Jaguar XK-E (won an impromtu drag race down the runway of the Breslau Airport), BMW Bavaria and a 4-wheel steering Honda Prelude.

In addition to camping and snowmobiling, his greatest recreational passions were power boating (cruisers Snowbird 1, 2 and. 3) and his sailing boat baby, the Nonsuch 30, Sailor, cruising/sailing Lakes Couchiching, Simcoe, Sparrow, Trent-Severn Canal and especially, the Georgian Bay 30,000 Islands. Murray was an avid member and leader in both the K-W Power Squadron and the Nonsuch member association, helping to organize many “rendezvous” gatherings and other events. (Murray was also a president of his local condo association.) Happily, he was also able experience sailing among the Caribbean islands. As well, Murray also recycled his passion for sailing into designing and arranging the manufacture and distribution of Nonsuch sailing boat hardware items.

Murray was also an avid RV’r. Reliving his early trucker days wheeling his Ford F-350 and 5th wheel trailer, many winters were spent exploring Florida, Texas and other southern locales.

Family, friends and acquaintances will be invited to gather to celebrate, relive and enjoy Murray’s full life in a relaxed, convivial setting. The celebration is tentatively planned for Saturday, September 1st, 2018. Full details will be promulgated at a date closer to the event through various means; MARK YOUR CALENDAR! The following day, close family will be invited to a scattering of Murray’s ashes, likely in the Georgian Bay area where he spent so much of his enjoyable times.

Murray Cressman, loving and devoted father and partner, motorcyclist, spelunker, trucker, salesman, innovative designer, power boater, sailor, beer maker, rum drinker and general all-round adventurer. Our Dad brought good times and hearty laughs. We will miss him greatly and will always love you.

Arrangements have been entrusted to the Henry Walser Funeral Home, 507 Frederick Street, Kitchener, 519-749-8467. Cremation has taken place. As expressions of sympathy, donations to the Lung Association (www.lung.ca) will be appreciated by the family (cards are also available at the funeral home).

Visit www.henrywalser.com for Murray’s memorial. You are also invited to leave a note, thought, expression.