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sailor3001
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Quote sailor3001 Replybullet Topic: ctrbrd sticks- new jy 15
    Posted: Jun 16 2008 at 6:37pm

Carey,

We had this problem with many new boats back in the early days at Fleet 25 in Texas (Hull no. less than 500).  JY15s had never lived in extreme heat before.  JY Sailboats said that the heat caused the interior foam to overexpand and bind up the centerboard.  The factory sent a rep to perform repairs.  As far as I know, none of our boats ever had this problem again.
I watched him and this is what he did. It is not a simple repair.
 
1 determine where along the length of the trunk that the board binds and mark for future reference
2 remove rig and flipboat upside down
3 remove centerboard gasket (flaps)
4 in the recess (both sides) where the flaps were removed,  cut out a 1/2 inch wide strip of the hull skin material along the length marked earlier. It is best to use a plunge router with a 1/2 inch bit and a guide bar to get a straight cut.
5 This next step is the one that no one ever believes. Use a small electric chain saw to remove the foam behind the walls of the CB trunk by inserting the saw vertically through the slots in the skin.  work carefully and slowly so that you dont penetrate the skin at the deck or the wall of the CB trunk.
6 protect the hull around the slots with tape and paper masking for the next step
7insert a wooden blank into the CB trunk to hold the walls at the desired spacing and refill the slots with expanding foam material
8 when the foam cures slice or sand off the excess that spills out of the slot.  The foam will need to be recessed so that you can glue in a new 1/2 inch strip of ABS plastic skin material. The ABS does not need have the special UV resistant coating that the original skin material has because it will be under the CB flaps when the repair is completed.  This should make it easier to find replacement materials.
9 the rep used the plexus adhesive to glue in the plastic strips to seal up the repair
10 any roughness in the repair should be sanded out so that the flaps will be smooth
11 replace the flaps with new ones as the old ones were most likely destroyed when removed.
12 rerig and sail
 
I do not know the dimension of the wood plug that was used to space the trunk walls or the specifics of the replacement expanding foam used to refill the slots.  This all took place back in the early 90s.  I had hoped that the problem would never come back.
 
Good Luck!
 
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Big Birdee
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Quote Big Birdee Replybullet Posted: Aug 08 2011 at 11:24pm
Thanks, I asked this question as "Stiff Centerboard", but then I read your reply to Cntbrd Sticks.
 
It sounds like a major repair for my skill level.  I think I will shave more off of my centerboard--- unless you advise against that.
 
It really is a hassle getting this thing up or down.
 
Best
brian
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sailor3001
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Quote sailor3001 Replybullet Posted: Aug 09 2011 at 8:29pm
Brian,

I would not shave down the centerboard. It is a highly loaded part of the boat and I wouldn't want it any thinner(weaker)than originally designed.

Mark
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Quote jodddrd624 Replybullet Posted: Jan 15 2013 at 6:38am
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Quote du3nxd9j7 Replybullet Posted: Jan 24 2013 at 8:22am
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Quote fyu191xq77 Replybullet Posted: Jan 30 2013 at 9:08am
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