A well respected yard just installed a horizontal electric windlass for me and I have a question about what they did (or rather what they didn’t do).
Mounting the windlass on deck required the yard to cut two holes–approximately 3" in diameter through the deck underneath the windlass. One hole is for the hawsepipe and the other is for the wiring. When I inspected their work this weekend, I was surprised to see that the balsa core at the edge of the two holes had not been sealed. Now, these areas should not normally be directly exposed to water, but they are above the chain locker with damp chain and rope.
Would you have expected the balsa core in the cut out holes to be sealed?
For comparison, I did check the boat’s original hawse and the balsa there does not look like it was sealed and it is solid after 31 years. So, maybe it’s ok.
Before I have a chat with the yard, I wanted to get some expert advice from the group on this.
It should absolutely been properly sealed. The edges of the hawspipe should have glass or resin partway into the core and the mounting holes should be drilled out oversized, filled and then drilled to the proper size. I’d be very concerned with that yard’s work.
Joe Valinoti
S/V IL Gatto NS30U #221
Sea Harbour YC
Oriental, NC USA
I don’t know what is considered normal in the industry, especially in your area. Most shops around here would not take the extra step because of the time involved. It becomes a cost issue. In his book “This Old Boat” Don Casey says that any where absorbent core is exposed around the perimeter of a cutout the core should be evacuated back and the resulting cavity filled with silica thickened epoxy (page 95 Second Edition). At a minimum the edge should be sealed with a epoxy. I would have thought that in the area effected part it would be plywood not balsa core, however either will rot if water gets in and the rot will spread. If the caulking around the hawsepipe or the wire fail the core will be exposed to rain water and seas breaking over the bow.
I don’t know what the access if like on the Ultra 30. On La Reina I can’t access the windlass with the mast in. If that is the case with Fate, and the shop won’t do anything, you should considered sealing the core the next time the mast is down. If you have access seal as soon as possible. Rotten deck core can be an expensive fix and the fore deck helps support the mast.
I’m not a professional by any means but I did install my own vertical windlass using a 4” teak block to raise the unit off the deck to the proper angle with the bow roller. I ABSOLUTELY sealed the core deck with epoxy everywhere I drilled or cut an opening as well as the edges of a plywood backing plate under the deck to add stiffness (maybe overkill but I like overkill). I sealed the block and all parts with BoatLife Life-Calk® Sealant. It may not be necessary to do what I did but I feel better having done it… don’t want water getting into the balsa core.
I just spoke to the yard and they agreed to seal the core where they drilled the holes for the new windlass. They also are sealing the core in the original hawsepipe that was never sealed. Thanks to all for your advice.