Fixing a leaking daggerboard casing

Previous sails have been hampered by a steady influx of water around the daggerboard casing.  It didn't stop me sailing but it was annoying being in a pool of water and having to bail out at every opportunity.  The problem was easily identifiable: the gasket hadn't been doing its job properly.  Additionally, whilst tightening up the six associated screws had some impact, the port side rear screw had sheared off leaving the tip embedded in the keel band and the remainder rotating freely.

I contacted Seahopper boats and Steve Cherry responded with a very helpful email.  These past few days have provided a window of opportunity to put into action his suggested remedy.

Removal of daggerboard; cleaning off.

Keelband showing removed hole for centreboard

 When removing the casing, there are six screws, two each side forward and aft removed from the inside, and a further two positioned centrally which attach from beneath the keel band.

The non-functioning gasket

Removal of gasket.

Application of sealant

Steve recommended a sealant called CT1 which is new to the market.  Currently, it doesn't seem to be widely available, but can be sourced online and from a firm called Buildbase.  There are several colours; the 'brown' variety seems to match nicely.

The idea is to apply liberal quantities of this sealant around the slot.  According to the blurb, it's versatile stuff and can even be applied under water...  Today, I chose the dry land option, building it up to around a centimetre in thickness.

Reattach daggerboard casing
The idea is to insert the four 'fore and aft' screws first, and locate these correctly - this helps ensure the casing is correctly positioned.  I had the additional job of relocating the rear port screw the original of which had sheared off.  Size 10, 11/2 inch brass screws seemed to match nicely although the heads were a little larger.

Following Steve's instructions, I tightened the four internal screws to a point where the sealant began to squirt out from beneath.

Removal of surplus sealant
Steve recommended running a finger around the edge of the box to smooth off the excess sealant. The same routine was repeated with the boat closed from beneath, working around the inside of the daggerboard slot.

Daggerboard in place, screws in place but untightened

Drying overnight.
It had to rain, didn't it.  Fortunately, this had been anticipated with a handy cover!

Once dry...
The following morning, I tightened the four screws and inserted new keelband screws from beneath.

Screws from beneath had slightly bigger heads.  These have been left slightly proud initially.  I may well turn them some more later in the season but will see how they go for now.

Completed repair from the stern.

The proof of the pudding will be in the...sailing (as they don't say).  Looking forward to an opportunity to put this to the test!

Further work to be done on the boat includes the purchase of new rigging - far too many frayed ends for my liking.   Also, there will have to be some repair work on damaged extremities of certain pieces of the various bits of marine ply which constitute the boat in its assembled form.

Finally, we have a name.  Aura.  It's Latin for 'breeze'.  Let's hope for fair aurae in 2016!