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This was slightly longer than the original because cast iron is heavier than rolled steel. From CYB we purchased new bronze keel hangers and pivot pin.

With these we made a plywood template to check that our drawing was correct before having the steel keel profile cut.

We made the keel 40mm thick which only just fitted the moulded hull slot. A bit judicious grinding of some protruding fibreglass soon had the template fitted. We were now ready to order our new steel keel. The original cast keel had a slight aerofoil shape to it that we could not replicate with flat steel plate so we faired the front and trailing edges by gas cutting and a lot of grinding. When this was complete we then had it hot dipped galvanised for protection.

Now all we had to do was fit it! The boatyard at Dellquay had been chosen because the boats were stored on a wooden platform at the foreshore. This enabled us to lift the boat onto wood props and remove some of the planks below giving us crouching room under the hull. We built two timber A- frames on each side of the hull and fitted lifting chain blocks to the A- frames. A scaffold pole was then passed through a hole in the keel that we had cut at the centre of gravity.

This enabled us to lift the keel up and then pivot it around the scaffold pole until we were able to place the bronze keel hangers and pivot pin into the correct location under the hull. Four holes were quickly drilled through the hull and into some extra strengthening fibreglass we had built up inside.

The bolts were coated with sealant and tightened up. Next was to fit an eyebolt for the lifting wire. This was a simple case of drilling and tapping the edge of the keel for the new eye. We did not fancy using stainless steel wire, for lifting the keel, as had been fitted before it had clearly snapped so we fitted Dyneema rope which is extremely strong and hard wearing.

We changed this after 3 years and it was still going strong with no sign of wear. We fitted a sacrificial anode to each side of the keel as there was rather a mixture of metals present, slapped some coats of primer and antifoul on and our new keel was complete.

We have sailed quite a few miles with no sign of problems of leaks or performance. See photos of Meriel here. Stephen Horrod.

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