[Public-List] Replace chainplate knees

[Brent Higgins via Public-List]

Hi Everyone, 
Happy spring! I have put this project off long enough. I need to replace myforward lower chainplate knee on the starboard side. It’s a disaster and I’mguilty of probably waiting too long than is safe. I posted a couple photos on the Facebook page along w/ this email. I’ve tried to do my due diligence and read as many threadson the public list/internet as possible and have the following plan, which I hope folkswith experience can validate (or correct where needed). The boat is on the hardfor this project. I am still a novice at boat repair and a little nervous. Herewe go:


   
   - On deck, loosen my forward lower shrouds on theport and starboard sides. I may also use my halyards hooked to port andstarboard deck cleats for some extra mast stability (not sure it’s necessary/helpful).
   - Remove starboard lower shroud from chainplate,then remove bolts/chainplate.
   - Next, cut away rotted knee using a flat blade onan oscillating multi-tool.
   - I had hoped to avoid replacing the shelf, but itdoes look beyond repair. So, I’ll likely cut it away entirely, salvaging theteak trim if possible.
   
   - Alternative is to just use some rot repair onthe rotted section and glass over it for strength. Seems a little lazy butwould get me through a few more seasons. I have future plans w/ the v-berth, soit could be nice to put this off awhile if safe.
   
   - Carefully grind away the old tabbing and cleanthe exposed material.
   - Template out knee on some cardboard or scrap.Once it fits, I have some 3/8” marine plywood. I was thinking I’d laminate 2 piecestogether for strength.
   - Patch or replace the shelf.
   - Dry fit the knee and chainplate but wait todrill any holes for the bolts.
   - Mix some thickened West System epoxy and apply abed of it on the points where new knee and deck/hull/shelf meet.
   - Setthe knee and let the epoxy kick.
   - Applytabbing in 3 layers, starting w/ something like 5” and working down.
   - Fiberglassthe knee in completely.
   - Fitthe chainplate, drill 5/16” holes for new bolts.
   - Bedchainplate in 4200, bolt together, tightening over the next day or two.
   - Caulkaround the chainplate on deck to seal and keep up with this regularly to avoid ever having to do this project again! I do not have chainplate covers.



Thoughts? One of the main reasons I bought the boat was to learn how to do this stuff, but when it comes to these really important structural components, I definitely don't want to take any chances. Thanks in advance :-)
Best,
Brenton
s/v Ethel Jean