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Boom Restoration

2011/05/22 - Managed to lower the boom off the deck to ground level without dropping it or hurting myself. (The boom weighs about 130 pounds and is 15 feet long.) I've been able to remove most of the hardware from the spar except for the gooseneck casting. It appears that the wood has gotten a bit wet and has swollen as the fitting is locked on tight and will not budge. The boom is sitting in the garage now, so with any luck it will dry out over the next few weeks and allow me to get the fitting off.

2011/06/12 - After two weeks of drying out, the gooseneck casting is still firmly attached to the end of the boom. Time to get serious.

A torch was used to gently heat the fitting to about 175°F so as not to blacken the wood. A hammer was then used to see if the fitting could be persuaded to come off. After a few taps, the fitting began to move and, after about 20 minutes, was free. Sanding of the boom could finally commence!

2011/07/01 - Using a wire brush, finished stripping out the slots in the boom for the sail track and outhaul. The boom is now ready for refinishing.

A coat of epoxy was brushed into the groove for the mainsail track as water tends to collect here. Hopefully this will prevent the wood from absorbing much water over the next few years.

2011/08/12 - The boom received its seventh and final coat of varnish today. Tomorrow the hardware will get buffed up and reinstalled so that room can be made in the shop for other projects.

2011/08/13 - Started the day by finishing the boom. The first step was to check the boom to make sure there were no rough spots that might need some touch up with varnish.

The next step was to reassemble the gooseneck/roller furling casting on the forward end of the boom. The pieces were cleaned and then put back together before being reattached to the boom. Here's an "exploded view" of the fitting for reference.

Moving to the aft end of the boom, the outhaul fitting needs to be put back into place.This photo shows the raw boom and how it is shaped to accomodate the outhaul assembly.

The photos below show the outhaul assembly and the assembly once it is fitted onto the end of the boom.

Next comes the sail track for the mainsail foot and its dozens of screws to tighten. Thank goodness for battery powered drills!

Next the cheek blocks for the slab reefing get attached to the boom. I've never had good luck with a roller reefing main when it comes to maintaining sail shape, so I put these blocks on a while back and they've worked quite well.

The boom, at this point, is now completely overhauled and ready to be put back on the boat, but this will be a 2-man job and will have to wait until the rest of the deck work is complete.

2012/06/23 - The boat has been hauled back to the marina and launched and the refinished boom is back in its rightful place!