Sailing Catalpa · video

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The crew of the 40-ft catamaran Catalpa fabricates a custom stainless steel boom vang fitting while anchored in El Salvador. The original alloy fitting failed due to galvanic corrosion where it met the stainless steel mast plate, causing the unit to break under load.21:34 Using 304 stainless steel plate, an angle grinder, and a 200-amp Eastwood TIG welder, the owner constructs a replacement part with an oversized footprint to allow for stitch welding directly to the existing mast plate, eliminating the need for bolts.14:10 The fabrication process includes drilling precise holes for the pin and block attachment using a shore-based drill press.2:18 Additionally, the crew performs an underwater inspection of the propeller shaft, discovering a depleted sacrificial anode.8:02 They install a temporary zinc anode as a stopgap measure until a proper shaft-mounted replacement is sourced.10:26 The project demonstrates that custom metal fabrication is often necessary for repairs in remote cruising locations where specific replacement parts are unavailable.

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