Repairs to keel sump

An update on Zapatero's repair:

Once hauled, we found there were no cracks in the hull laminate, just in some fairing putty and the bottom paint.

The structural grid had become disbonded from the hull for a distance of about 1 foot, either side of the sump.  The sump remained bonded and there were cracks that went completely through the grid laminate with a length of an inch or two at the junction between the sump and the transverse beams (floors).

We repaired as follows:

Cut out the structural grid for a total width of about 5 feet and for a distance about 6 inches beyond the front and back ends of the keel sump.  Ground out the grid laminate from the sump.

Added 1.5 oz mat, 24 oz woven roving (WR), mat, WR, then two layers of 8.6 oz unidirectional (uni) to the hull, including the sump.  All were laminated with epoxy laminating resin. WR and uni were S-glass.  Unis were run in the athwartships direction.

Built floors from 2x douglas fir.

laminated mat, WR, and Unis over the douglas fir floors, using approximately the same schedule as for the hull, above.  Laminations extended across the entire area of the hull laminated above.

reinstalled the original structural grid over the new laminated grid.  The old grid was tab-laminated onto the hull with mat, WR and epoxy.  cut joints in the old grid were ground out and taper-laminated with mat, WR and polyester resin, since the old grid was polyester.

Furniture is now being put back in the boat.