Replacing my bulkhead and compression post

[Mary Mac]

Last year after buying this 1978 CAL 34-III, I found that there was a leak through the mast wire hole. It was all covered by trim. It had rotted a portion of the top of the compression post and some of the bulkhead.

I want to fix it right, but I’m on a tight budget. I tried removing the compression post and repairing the wood with penetrating epoxy after consulting with Total Boat. It isn’t strong enough, since a chunk of the wood is missing. I’ve called around to get prices on white ash, which is much more affordable than teak for the compression post. Does anyone have experience with using alternatives to teak? A piece of teak is around $600 compared to $150 for the ash.

The bulkhead seems like a total pain to replace. I would have to do it in sections, since the whole thing wouldn’t fit through the companionway. I’m wondering if I can cut out the side that is rotten and replace it. I’m also not sure if it is rotten near the chainplate. I resealed the chainplate last summer, but it still gets a little damp and the wood is discolored. I should probably do the whole thing. Anyone know someone who does this kind of work in the SF Bay Area?

I’m hoping to find a place that can pull the mast so I can fix the leak.

Pics of me putting the teak post back in, since it’s stronger than the 2x4s.

[thebastidge]

Teak is wonderful wood. Very rot-resistant, dense and strong.

But it's not the only game in town. Boat building in the northern hemisphere went on a long time before they were aware of teak. A nice white oak post would not run anything like $600. I've seen people on other forums replacing their compression post with things other than teak. Some of them more worried about the color difference than anything else, but even getting good quality teak can be a problem these days, with some teak from plantations being too broad-grained from growing too quickly, and therefore less strong than a fine-grained piece.

I've even seen people replacing compression posts with a metal post. A lot of sailors certainly seem to be more concerned with aesthetics and tradition than practicality, but you see a whole lot of variation in approach.

[Mary Mac]

I originally cut out just the rotten part of the bulkhead, but today I cut out more. I got a sheet of 3/4 hydrotek with mahogany veneer to replace that section. It was a total pain to figure out the best way to cut it since nothing is square in here! That metal thing worked great as a fence for the circular saw. I finished off the ends with the Japanese saw and the multi-tool. The hydrotek won't match the original, so I am thinking I'll put another layer of veneer across the whole thing or just leave it.

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[Mary Mac]

New hydrotek in place (dry-fit). Have to even out the bottom of the cut on the existing bulkhead for a perfect fit where the circular saw wouldn't reach. The hydrotek is very dry, soft and splinters easily. I expected a nicer veneer. They said it was Mahogany.

I was thinking I'd cover it with a veneer, but I think it might be interesting to add a shallow shelving unit behind where the table folds up instead. Would have to modify the table a bit.

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[Mary Mac]

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