rhino removal and install.pdf

COLLAR SYSTEM

SECTION 180 FOUNDATIONS

180-1

INTERNATIONAL, LLC

8800 SW Barney White Rd Port Orchard, WA 98367

(360)674-7161

Collar Inspection, Maintenance, Removal and Re-Installation Procedures

180-3

Section Title

180 General

180-1 Inspection Frequency

180-2 Inspection Types

180-3 Inspection Determination and Repair Preparation

180-4 Repair Procedures

Table of Contents

180-5 Repair Tools Required

180-6 Collar Removal

180-7 Removal Tools Required

180-8 Collar Re-Installation General

180-9 Re-Installation Tools Required

180-4

List of Tables

Table Title

180-2.1 1/4 inch Seam Inspection

180-2.2 3/4 inch and 2 inch Seam Inspection

180-2.3 Flange Seal Inspection

180-4.1 Flange Seal Repair

180-4.2 Expansion or Installation of 2 inch Collar Seam

180-4.3 Repair of 2 inch Collar Seam

180-6.1 Collar Removal

180-8.1 Collar Re-Installation

180-3.3 Preparation for Repair of 2 inch Collar Seam

180-3.2 Preparation for Expansion or Installation of 2 inch Collar Seam

180-3.1 Preparation for Flange Seal Repair

180-1.1 Inspection, Preparation, Upgrade and Repair Procedure Sequences

180-5

List of Figures

Figure Title

180-1a Lower Collar Seam

180-5a Repair Tools

180-5b Tool Kit

180-5c Stainless Steel Wire Wheel

180-5d Collar

180-3.1a Masking

180-3.2a Masking

180-4.1a Flange Seal Repair Application

180-4.1b 5 lb. Dead-blow Hammer

180-4.2a Masking

180-4.2b Smoothing Collar Seam

180-4.2c Tape Removal

180-4.3a Smoothing Collar Seam

180-4.3b Tape Removal

180-7a 2 inch Wide Pry Bar

180-7b 5 lb Dead-blow Hammer

180-7c 4 foot Pry Bar

180-6.1a Breaking Flange Seal

180-6.1b Separating Collar and Flange

180-6.1c Aft Collar Separation

180-9a Re-installation Tools Required

180-9b Consumables Needed

180-6

List of Figures

Figure Title

180-8.1b Flange Measurement Transfer

180-8.1c Aluminum Block and UHMW Rod

180-8.1d Flange Distance Measurement

180-8.1e Masking Off Side Sheet

180-8.1f Aft End Side Sheet

180-8.1g Masking Lower Flange Edge

180-8.1h Nose cone Placement

180-8.1j Block Sealant Application

180-8.1k Lower Flange Sealant Application

180-8.1m Sealant Application Aft End Side Sheet

180-8.1n Collar Installation

180-8.1p Personnel Recovery Cutout Alignment

180-8.1q Seating Collar

180-8.1r Securing Collar Blocks

180-8.1s Lower Collar Taped Off

180-8.1t Lower Flange Seal Application

180-8.1u Collar Seam Application

180-8.1v Masking Tape Removal

180-8.1w Lower Collar Seam

180-8.1x Performance Fin Leading Edge

180-8.1a Lower Flange Measurement

180-7

180 Collar System

180 General The flange seal is the polyurethane seal between the collar and the lower four inch metal flange (3, figure 180-1a), located at the waterline and runs from the performance fin to the bow.

The collar seam (2, figure 180-1a), is the external cap of 3M 540 Polyurethane Sealant which covers the lower metal flange edge where it meets the collar. This collar seam adheres to the flange seal and is applied during installation from the leading edge of the performance fin to the bow.

The collar seam prevents water from degrading the flange seal and allowing the intrusion of water below the collar and against the hull structure. Intrusion of water over time can damage the collar beyond repair.

The finished appearance of the collar seam should be 2 in., in overall width. 1 in. on the collar coating and 1 in. on the lower flange. This is the approved overall seam width.

Use only 3M 540 Polyurethane Sealant.

180-1 Inspection Frequency

The collar seam and flange seal inspections should be performed every time the boat is out of the water, bi-monthly or every 50 hrs of service. In the event the collar is significantly damaged, (flange seal damaged more than 40%), weight the boat to determine necessity for repair or replacement. Document and contact SAFE Boats Intl. to verify collar warranty prior to proceeding with removal of damaged collar.

Follow table 180-1.1 for inspection, preparation, upgrade and repair procedure sequences.

180-8

180-2 Inspection Types

Inspection of the collar seam and flange seal should be performed every time the boat is out of the water, bi-monthly or every 50 hrs of service.

There are four types of collar seams that can be found on SAFE Boats.

1. No collar seam. Refer to table 180-2.3 for flange seal inspection procedure.

2. Collar seam of 1/4 in. wide, running along the edge of the collar, meeting the flange edge. Refer to table 180-2.1 for 1/4 in. collar seam inspection procedure.

3. Collar seam of 3/4 in. wide, overlapping the flange to the collar. Refer to table 180-2.2 for 3/4 in. and 2 in. collar seam inspection procedure.

4. Collar seam of 2 in. wide, overlapping and providing a smooth transition from the flange to the collar. Inspection procedure is the same as table 180-2.2 for 3/4 in. and 2 in.

collar seam inspection procedure.

If damage to the collar seam is found, refer to table 180-2.3 for flange seal inspection procedure.

180-3 Inspection Determination and Repair Preparation

In the event the collar is significantly damaged, (flange seal damaged more than 40%), weight the boat, document findings, and contact SAFE Boats Intl. to determine the best way to proceed. Do not remove the collar before contacting SAFE Boats Intl.

Repair preparation needs to be performed prior to any repair of the flange seal or the collar seam. Refer to the following tables:

180-3.1 Preparation for Flange Seal Repair

180-3.2 Preparation for Expansion or Installation of 2 inch Collar Seam

180-3.3 Preparation for Repair of 2 inch Collar Seam

180-9

180-4 Repair Procedure

Before performing any repairs, ensure collar seam inspection, flange seal inspection and preparation procedures are complete and have been documented.

Refer to table 180-4.1 for flange seal repair.

Refer to table 180-4.2 for expansion or installation of 2 inch collar seam.

Refer to table 180-4.3 for repair of 2 inch collar seam.

180-10

No Collar Seam

180-2.3 Flange Seal Inspection

180-3.1 Preparation for flange seal repair

180-3.2 Preparation for expansion or installation of 2 inch collar seam

180-4.1 Flange Seal Repair

180-4.2 Expansion or installation of 2 inch collar seam

1/4 inch Wide Collar Seam

180-2.1 1/4 inch seam inspection

180-2.3 Flange seal inspection

180-3.1 Preparation for flange seal repair

180-3.2 Preparation for expansion or installation of 2 inch collar seam

180-4.1 Flange seal repair

180-4.2 Expansion or installation of 2 inch collar seam

3/4 inch Wide Collar Seam

180-2.2 3/4 inch and 2 inch seam inspection

180-2.3 Flange seal inspection

180-3.1 Preparation for flange seal repair

180-3.2 Preparation for expansion or installation of 2 inch collar seam

180-4.1 Flange seal repair

180-4.2 Expansion or installation of 2 inch collar seam

180-2.2 3/4 inch and 2 inch seam inspection

180-2.3 Flange seal inspection

180-3.1 Preparation for flange seal repair

180-3.3 Preparation for repair of 2 inch collar seam

180-4.1 Flange seal repair

2 inch Wide Collar Seam

180-4.3 Repair of 2 inch collar seam

Table 180-1.1.

Inspection, Preparation, Upgrade and Repair Procedure Sequences

180-11

Figure 180-1a. Lower Collar Seam

1. Collar 3. Lower Flange

2. 2 in. Collar Seam

180-12

180-5 Tools Required

The following tools are required to perform maintenance on the lower collar seal:

Figure 180-5a. Tools

1. Variable Speed Grinder/Buffer (under 6000RPM)

6. Clean Rags

2. Two 2 in. Curved Pry Bars 7. Flashlight

3. Caulking Gun 8. Permanent Marker

4. 5 lb Dead-blow Hammer 9. Tape Measure

5. Acetone

180-13

180-5 Tools (cont.)

The following are tools included in SAFE Boats International Lower Seal Maintenance Kit P/N HDWR0644: part numbers listed below can be purchased individually.

3M Scotch Seal Polyurethane Sealant 540, P/N 540 3M Scotch-brite Bristle Brush, P/N 27606, 80 Grade, 6 in. dia:SBI

P/N SHOP1125

5/8 in. Retaining Nut, SBI P/N SHOP1144 (for attachment of

Brush)

Figure 180-5b. Tool Kit

1. Protective Gloves 5. Backing Plate

2. 2 in. Masking Tape 6. 5/8 in. Retaining Nut (for attachment of Brush)

3. 3M Scotch Seal Polyurethane Sealant

7. 80-Grit Sandpaper

4. 3M Scotch-brite Bristle Brush

180-14

Figure 180-5c. Stainless Steel Wire Wheel

180-15

1. Foam Collar

2. Flange Seal

3. Performance Fin

Figure 180-5d. Collar

180-16

Table 180-2.1. 1/4 inch Collar Seam Inspection Procedure

Step Action

Note 1: Recommend using two persons to perform inspection.

1. Inspect the collar seam for damage from the performance fin to the bow. Using the butt end of a hammer, push against the collar 2 in. from the metal flange. If the seam moves independently from the metal flange edge, the seal has been damaged and requires repair.

2. Identify any loose or damaged area with masking tape.

3. If damage to the collar seam is found, proceed to table 180-2.3 for flange seal inspection.

4. If no damage to the collar seam is found, document and place vessel back in service.

180-17

Table 180-2.2. 3/4 inch and 2 inch Collar Seam Inspection Procedure

Step Action

Note 1: Recommend using two persons to perform inspection.

1. Inspect the collar seam for centerline cracks the full length of the collar seam, from the performance fin to the bow. If the collar seam has centerline cracks the seam has been damaged and requires repair.

3. If damage to the collar seam is found, proceed to table 180-2.3 for flange seal inspection.

2. Identify any loose or damaged areas with masking tape.

4. If no damage to the collar seam is found, document and place vessel back in service.

180-18

Table 180-2.3. Flange Seal Inspection Procedure

Step Action

1. Ensure that necessary collar seam inspection has been performed and findings have been documented.

Note 1: Recommend using two persons to perform inspection.

Note 2: An undamaged collar will be tight to the lower flange.

2. Inspect the seal for damage by using the 2 inch curved pry bar (2, 180-5a), angled down toward the flange. Carefully attempt to insert the tool between the collar and the lower flange.

3. Identify any areas where the pry bar can be inserted more than 1

in. by marking with a piece of masking tape. These are damaged areas and will require repair.

4. If damage to the flange seal is found, proceed to table 180-3.1 for preparation for flange seal repair.

Note 3: Be careful not to pierce the collar coating.

5. If no damage to the flange seal has been found, proceed to one of the following tables specific to boat collar seam.

Table 180-3.2 preparation for expansion or installation of 2 inch collar seam.

Table 180-3.3 preparation for repair of 2 inch collar seam.

180-19

Table 180-3.1. Preparation for Flange Seal Repair

Step Action

WARNING

When working with Acetone, gloves, safety glasses and a face mask are recommended. Failure to comply may result in personnel injury.

Note 1: Recommend using two persons for preparation.

Note 2: Do not use a straight edge for cleaning out damaged flange seal. Un-repairable damage to the collar may occur. View training video for example of process.

Note 3: Be careful not to pierce the collar coating.

2. Using two, 2 in. curved pry bars (2, figure 180-5a), acetone, and new shop rags (cloth); insert first pry bar at damaged area between collar and flange, angled down toward the flange. Lift collar to provide access for cleaning.

3. Apply acetone to new shop rag. Using second curved pry bar angled down toward the flange, insert shop rag with acetone applied into damaged area. Moving side to side, clean area until shop rag is relatively free of debris and dirt.

Note 4: Collar dry out time will be determined by level of damage, temperature and humidity.

4. Ensure that area(s) identified for repair are clean and dry.

Compressed air can be used to assist with the process. If the area(s) continue to weep water over a prolonged period of time, call the Collar Department at SBI for instructions on how to proceed.

5. Proceed with collar preparation procedure necessary for complete repair.

Table 180-3.2 for preparation for expansion or installation of 2 inch collar seam.

Table 180-3.3 for preparation for repair of 2 inch collar seam.

1. Ensure that collar seam inspection and flange seal inspections have been performed and findings have been documented, prior to proceeding with repairs.

180-20

Table 180-3.2.

Preparation for Expansion or Installation of 2 inch Collar Seam

Step Action

WARNING

When working with Acetone, gloves, safety glasses and a face mask are recommended. Failure to comply may result in personnel injury.

Note 1: Recommend using two persons for preparation.

2. Ensure that area(s) identified for repair are clean and dry.

Compressed air can be used to assist with the process. If the area(s) continue to weep water over a prolonged period of time, call the Collar Department at SBI for instructions on how to proceed.

Note 3: Be careful not to pierce the collar coating.

Note 4: Do not use the SS wire wheel on the collar as it can cause un-repairable damage to the collar.

3. Using 80 grit sandpaper (7, figure 180-5b), scuff a 1 in. thick strip of exposed collar skin and existing collar seam, the full length of the collar seam. This is to promote adhesion of the sealant.

4. Using 80 grit sandpaper (7, figure 180-5b), on the flange edge, scuff a 1 inch thick strip of exposed flange and existing collar seam, the full length of the collar seam. This is to promote adhesion of the sealant.

5. Clean scuffed area with clean rag and acetone.

1. Ensure that collar seam inspection, flange seal inspection, and flange seal preparation, have been performed and findings have been documented prior to proceeding.

180-21

Figure 180-3.2a. Masking

Table 180-3.2.

Preparation for Expansion or Installation of 2 inch Collar Seam

(cont.)

Step Action

7. Mask the collar, the entire length of collar seam in one continuous strip, parallel to the edge of the lower flange. Leave a 1 inch strip from the edge of the flange (figure 180-3.2a).

6. Using measuring tape, permanent marker, and 2 in. masking tape;

in one continuous strip, mask the entire length of the lower aluminum flange from the leading edge of the performance fin to the bow. Leaving a 1 inch exposed area along the flange edge.

8. If damaged was found to the flange seal, proceed to table 180-4.1 for flange seal repair.

Note 5: Ensure 5 inches of the leading edge of the performance fin is taped off.

9. If no damage was found to the flange seal, seal was intact, proceed to table 180-4.2 for expansion or installation of 2 inch collar seam.

180-22

Table 180-3.3. Preparation for Repair of 2 inch Collar Seam

Step Action

1. Ensure that collar seam inspection, flange seal inspection, and flange seal preparation, have been performed and findings have been documented prior to proceeding.

WARNING

When working with Acetone, gloves, safety glasses and a face mask are recommended. Failure to comply may result in personal injury.

Note 1: Recommend using two persons for preparation.

2. Ensure that area(s) identified for repair are clean and dry.

Compressed air can be used to assist with the process. If the area(s) continue to weep water over a prolonged period of time, call the Collar Department at SBI for instructions on how to proceed.

Note 3: Be careful not to pierce the collar coating.

Note 4: Do not use the SS wire wheel on the collar as it can cause un-repairable damage to the collar.

3. Where there is damage to the collar seam, scuff with 80-grit sandpaper to promote adhesion of repair sealant. Extend the scuffed area at least 6 inches beyond damaged area to ensure good adhesion.

4. Clean scuffed areas with clean rag and acetone.

180-23

Figure 180-3.3a. Masking for Flange Seal Repair

Table 180-3.3. Preparation for Repair of 2 inch Collar Seam (cont.)

Step Action

5. Using 2 in. masking tape; mask the underside of the lower aluminum flange and collar, on either side of the existing collar seam. Extend the masking at least 6 inches beyond the damaged area.

6. If damage was found to the flange seal, proceed to table 180-4.1 for flange seal repair.

7. If no damage to the flange seal was found, flange seal intact, proceed to table 180-4.3 for repair of 2 inch collar seam.

180-24

Table 180-4.1. Flange Seal Repair

Step Action

Note 2: Ensure metal flange is snug against the collar by gently tapping the flange using a 5lb. dead-blow hammer until it is.

2. Where the flanged seal is damaged and has been prepared for repair, inject a tube of 3M 540 polyurethane sealant (figure 180- 4.1a), deep into the gap between the collar and lower flange, with excess material exiting the gap. This is to re-bond where the collar sits on the metal flange (flange seal), not the exterior edge (collar seam).

3. If flange seal is damaged at performance fin, ensure that the sealant extends 5 inches along the angled leading edge of fin (figure 180-4.1b).

1. Ensure collar seam inspection, flange seal inspection and preparation procedures are complete and have been documented.

Figure 180-4.1a. Flange Seal Repair Application

180-25

Table 180-4.1. Flange Seal Repair (cont.)

Step Action

4. Immediately proceed to the appropriate collar seam repair procedure:

180-4.2 for expansion or installation of 2 inch collar seam.

180-4.3 for repair of 2 inch collar seam.

Figure 180-4.1b. 5 in. Seam Extension at Performance Fin

180-26

Figure 180-4.2a. Masking

Table 180-4.2. Expansion or Installation of 2 inch Collar Seam

Step Action

1. Ensure collar seam inspection, flange seal inspection, preparation procedures, and any necessary repair to the flange seal are complete.

2. Install the collar seam by applying one thick bead down the center of the taped off area (figure 180-4.2a), enveloping the metal flange edge. This will require at least one tube of sealant.

180-27

Step Action

Table 180-4.2. Expansion or Installation of 2 inch Collar Seam

4. Immediately apply a second bead of 3M 540 polyurethane along the center of the first laid seam.

5. Smooth all excess material with a plastic spreader (figure 180- 4.2b), in one continuous motion. Hold the spreader with two hands to create a convex shape. The seam should be 1/8 in. thick in the center, tapering to 0 in. at the tape edges. The result is a convex shape.

3. Smooth all excess material with a plastic spreader (figure 180- 4.2b), in one continuous motion.

Note 2: The thickness of the sealant over the relatively sharp corner of the aluminum performance fin and flange, should be thick enough so that the corner or edge does not cut through the sealant (approximately 1/8

in. thick).

Note 3: Ensure complete coverage between the 2 inch masked off area.

Figure 180-4.2b. Smoothing Collar Seam

180-28

Table 180-4.2. Expansion or Installation of 2 inch Collar Seam (cont.)

Step Action

6. Remove all tape immediately by peeling tape back against itself (figure 180-4.2c), to diminish “drips” or sags in the new seam.

Note 3: If the metal flange edge is visible after coating, a 2nd coat is recommended; this can be performed as soon as the 1st coat is half set (usually about 6 hrs at 70ºF).

7. Allow 24 hours at 70ºF for sealant to cure fully before placing back in service.

Figure 180-4.2c. Tape Removal

180-29

Table 180-4.3. Repair of 2 inch Collar Seam

Step Action

1. Ensure collar seam, flange seal inspection procedures, preparation procedures, and any necessary repairs to the flange seal have been completed before continuing.

2. Apply one thick bead of 3M 540 polyurethane sealant down the center of the masked off area; extending onto existing 2 inch collar seam, enveloping the metal flange edge.

Note 1: The thickness of the sealant over the relatively sharp corner of the aluminum performance fin and flange, should be thick enough so that the corner or edge does not cut through the sealant (approximately 1/8 in.

thick).

3. Smooth all excess material with a plastic spreader (figure 180- 4.3a), in one continuous motion. Hold the spreader with two hands to create a convex shape. The seam should be 1/8 in. thick in the center, tapering to 0 in. at the tape edges. The result is a convex shape.

Figure 180-4.3a. Smoothing Collar Seam

180-30

Table 180-4.3. Repair of 2 inch Collar Seam (cont.)

Step Action

Note 2: If the metal flange edge is visible after coating, an additional coat is recommended. This can be performed immediately.

4. Remove all tape immediately by peeling tape back against itself (figure 180-4.3b), to diminish drips or sags in the new seam.

5. Allow 24 hours at 70ºF for sealant to cure fully before placing back in service.

Figure 180-4.3b. Tape Removal

180-31

180-7 Tools Required

The following tools are required for collar removal:

Two, 2 in. wide curved pry bars

Five pound dead-blow hammer

3/4 in. socket and ratchet

4 foot pry bar

WARNING

Removal of the collar may damage or reveal damage to the collar that makes it inadequate for repair and reinstallation. Contact SAFE Boats International (SBI) prior to beginning removal of collar.

180-6 Collar Removal

In the event the collar is significantly damaged, (flange seal damaged more than 40%), weight the boat to determine necessity for repair or replacement, document and contact SAFE Boats Intl. for verification and requirements on collar re-installation warranty, prior to proceeding with removal or re-installation of collar. Removing the collar could potentially damage the collar beyond repair. Contact SAFE Boats, Intl. prior to proceeding with table 180-6.1 for collar removal.

Figure 180-7a. 2 Inch wide Pry bar

180-32

Figure 180-7b. Five Pound Dead-blow Hammer

180-33

Figure 180-7c. Four Foot Pry Bar

180-34

Table 180-6.1. Collar Removal Procedure

Step Action

1. Beginning at the bow, carefully begin to insert the pry bar, angled downward, between the collar and the lower metal flange (figure 180-6.1a), breaking the flange seal.

2. Tap the pry bar with a five pound dead-blow hammer to insert the pry bar between the collar to the lower metal flange.

Note 1: Permanent damage to the collar can occur if up pressure is not applied while driving the pry bar between the collar and flange.

3. Push up on the pry bar while driving in with the five pound dead-blow hammer until it reaches the metal side sheet.

Note 2: Be careful not to cut into the collar skin.

4. Swivel the pry bar side to side to release the 540 polyurethane seal.

Figure 180-6.1a. Breaking Flange Seal

180-35

Table 180-6.1. Collar Removal Procedure (cont.)

Step Action

5. Repeat process every two inches (figure 180-6.1b), the entire length of the collar. The pry bars will insert easily in areas were the 540 polyurethane seal has already been broken.

Note 3: Pay attention to the area of the collar bolt where it threads into the block on the side of the boat. Take photos of the collar bolt if damage is found.

6. When the bottom of the collar has been completely released from the lower flange, remove the collar bolts and inspect for damage.

Figure 180-6.1b. Separating Collar and Flange

180-36

Table 180-6.1. Collar Removal Procedure (cont.)

Step Action

7. With all collar bolts removed, insert the four foot pry bar between the collar and the metal side sheet at the aft end, just below the aft capture plate (figure 180-6.1c).

Note 4: Some adhesive may be on the back of the collar at the lower corner making removal difficult. Be careful not to rip the coating on the back of the collar.

8. Carefully begin to pull the collar away from the boat. Use the 2 inch wide pry bar to separate the adhesive from the side sheet of the boat and release the collar.

Figure 180-6.1c. Aft Collar Separation

1. Aft Capture Plate 4. Four Foot Pry Bar

2. Collar 5. Metal Side Sheet

3. Lower Flange

180-37

Table 180-6.1. Collar Removal Procedure (cont.)

Step Action

9. Slide the collar aft to release it from the metal bow.

10. Inspect the entire removed collar for damage. Take detailed photos and document damage. Contact SAFE Boats, Intl. for direction on how to proceed.

11. Refer to table 180-8 for collar re-installation.

180-38

180-8 Collar Re-Installation General

In the event the collar is significantly damaged, (flange seal damaged more than 40%), weight the boat to determine necessity for repair or replacement, document and contact SAFE Boats Intl. for verification and requirements on collar re-installation warranty, prior to proceeding with removal or re-installation of collar. Refer to table 180-

8.1 for collar re-installation.

180-9 Tools Required

The following is a list of tools required for collar re-installation (figure 180-9a).

Air line and air hose Five lb dead-blow hammer Tape measure 3/4 in. socket with ratchet 3M Bristle Brush 4 inch Stainless Steel Wire Brush Ft/lb Torque wrench Variable speed grinder 10 in. vice grips Needle nose pliers (for opening 3M Polyurethane Sealant) Permanent Marker Small flashlight Caulking gun

Consumables needed (figure 180-9b):

Clean rags 2 in. Masking tape Acetone 80 Grit Sandpaper 4 in. Plastic Spreader Disposable gloves Respirator Mask Safety Glasses/goggles

Parts required:

7—9 tubes of 3M 540 Polyurethane Sealant (per collar)

Potential parts required:

UHMW White rod #COLL0003 UHMW Black collar keeper #COLL0002 1/2 in. SS Lag bolt Sherwin William’s water-based industrial enamel (side sheet paint) B53 B 300, 6403 3027

180-39

1. Air Line and Air Hose 7. Variable Speed Grinder

2. Five lb Dead-blow Hammer 8. 10 inch Vise Grips

3. Tape Measure 9. Needle Nose Pliers

4. 3/4 inch Socket w/Ratchet 10. Permanent Marker

5. 4 in. SS Wire Brush and Grinder 11. Small Flashlight

6. Ft/Lbs Torque Wrench 12. Caulking Gun

Figure 180-9a. Required Tools

180-40

1. Clean Rags 4. 80 Grit Sandpaper

2. 2 inch Masking Tape 5. 4 inch Plastic Spreader

3. Acetone 6. Disposable Gloves

Figure 180-9b. Consumables Needed

180-41

Table 180-8.1. Collar Re-Installation

Step Action

1. Measure the width of the lower flange (figure 180-8.1a). Example below is four inches.

Figure 180-8.1a. Lower Flange Measurement

180-42

Table 180-8.1. Collar Re-Installation (cont.)

Step Action

2. Transfer the same measurement, plus one inch, using a permanent marker, to the collars lower edge (figure 180-8.1b).

This is where the collar rests on the lower flange.

CAUTION

Be careful not to grind too deeply into the collar.

WARNING

When working with Acetone, gloves, safety glasses and a face mask are recommended. Failure to comply may result in personnel injury.

3. With 80 grit sand paper, scuff the exterior sealant on the collar to promote adhesion of the 3M 540 polyurethane seal.

Note 1: To prevent damage to the collar, only use the 3M bristle brush. Be careful not to grind too deeply.

Remove just enough of the old sealant to allow the new sealant to bond properly.

Figure 180-8.1b. Flange Measurement Transfer

180-43

Table 180-8.1. Collar Re-Installation (cont.)

Step Action

WARNING

Provide adequate ventilation when working with Acetone.

Failure to comply may result in serious injury to personnel.

4. Wipe area with clean rag and acetone.

5. Ensure that there are three holes in the aluminum collar block (figure 180-8.1c). They should all be 7/16 in. diameter and 3/4 in.

center to center from one another. The depth of the hole should not penetrate the side sheet.

6. Ensure that there is a white UHMW rod inserted into the aluminum collar block and drilled.

7. Ensure all holes are free and clear of adhesive.

Figure 180-8.1c. Aluminum Block and UHMW Rod

180-44

Table 180-8.1. Collar Re-Installation (cont.)

Step Action

9. Ensure the distance between upper and lower flange is 24 in.

(figure 180-8.1d). If necessary tap lower collar flange out with a five lb dead-blow hammer to provide correct distance for installation.

10. Wipe clean with rag and acetone.

8. Using the variable speed grinder and SS wire brush, scuff the lower flange until free of old sealant.

Note 2: Corrosion resistant paint should be on side sheet, channel and collar blocks. Touch up if required.

Paint should not be on lower flange.

Figure 180-8.1d. Flange Distant Measurement

180-45

Table 180-8.1. Collar Re-Installation (cont.)

Step Action

Note 3: Use two persons to mask off side sheet.

11. Apply two rows in a single strip of two inch masking tape to the side sheet, running the length from bow to stern (figure 180-8.1e), stopping two inches from the stern (figure 180-8.1f). Masking prevents excess 3M 540 polyurethane sealant from bonding the collar to the side sheet.

Note 4: Tape should cover the flange weld seam along the bottom of the side sheet.

Note 5: Ensure that the tape on the side sheet does not go completely to the aft end of the side sheet. Leave approximately two inches.

Figure 180-8.1e. Masking Off Side Sheet

180-46

Table 180-8.1. Collar Re-Installation (cont.)

Step Action

Figure 180-8.1f. Aft End of Side Sheet

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

12. Scuff bottom edge of lower flange, approximately one inch from the flange edge using a variable speed grinder and SS wire brush.

Note 6: Ensure the five inches of the leading edge of the performance fin is scuffed to ensure proper adhesion of the collar seam.

14. Tape off under the lower flange with a continuous strip of two inch masking tape, leaving one inch of the flange edge exposed (figure 180-8.1g).

13. Wipe bottom edge of lower flange and performance fin with clean rag and acetone.

Figure 180-8.1g. Masking Lower Flange Edge

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

Note 7: Recommend three or more persons when placing collar.

15. Dry fit the collar. Verify bolt hole alignment with flashlight and insert bolts. Ensure the Personnel Recovery Cutout (PRC) is aligned; 1/4 in. gap is acceptable. Gap can be tapped down once collar is installed.

Note 8: This is done to avoid removing the collar and refitting after the 3M 540 polyurethane sealant has been applied.

16. Apply a piece of masking tape on the collar to mark where it sets at the nose cone (figure 180-8.1h). This ensures proper fit after the 3M 540 polyurethane sealant has been applied.

Figure 180-8.1h. Nose Cone Placement

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Step Action

18. Apply 3M 540 polyurethane sealant to the center hole of all the collar blocks (figure 180-8.1j). Sealant can be applied to the tip of the lag-bolt if center hole is not used.

Table 180-8.1. Collar Re-Installation (cont.)

17. Remove collar after dry fit.

Figure 180-8.1j. Block Sealant Application

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Step Action

19. Apply four tubes of 3M 540 polyurethane sealant in a serpentine pattern to the lower flange (figure 180-8.1k). Sealant is applied from the weld at the bow to the aft end of the flange. This is the flange seal.

Table 180-8.1. Collar Re-Installation (cont.)

Note 9: Maintain contact with the tip of the 3M 540 polyurethane sealant applicator. This ensures complete coverage.

20. Apply a bead along the outer edge of the flange, connecting the serpentine edge.

Figure 180-8.1k. Lower Flange Sealant Application

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

Note 10: Do not apply 3M 540 polyurethane sealant on the welded corner. This allows water to drain, if necessary.

21. Apply a bead of 3M 540 polyurethane sealant at the lower aft edge of the side sheet (figure 180-8.1m), leaving one inch at lower corner where the side sheet meets the lower flange.

Figure 180-8.1m. Sealant Application Aft End of Side Sheet

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

22. With three or more people, insert the bow end into the metal bow flange (figure 180-8.1n).

Note 11: Keep the aft end of collar well away from the hull.

23. Set the collar into the bow flange with the tape line that was placed during dry fit aligned with bow flange edge.

Figure 180-8.1n. Collar Installation

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

24. Push the aft end of collar up to the boat ensuring the Personnel Recovery Cutout (PRC) is aligned (figure 180-8.1p). A gap of 1/4

in. is acceptable. The gap can be tapped tight. If absolutely necessary, pull collar away from boat and slide forward or aft until alignment is made.

Figure 180-8.1p. Personnel Recovery Cutout Alignment

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

25. When PRC aligns, use the five lb dead-blow hammer to tap the collar into the aluminum flange (figure 180-8.1q), if necessary.

Note 12: Do not hit the aluminum flange.

26. Once the aft end is in place there will be a buckle or bow at mid-ship. Use the five lb dead-blow hammer to tap the collar into the flange while another person pushes the collar up to the side sheet, until collar is fully seated.

Figure 180-8.1q. Seating Collar

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Step Action

27. Using 10 inch vise grips, attach collar blocks by inserting the bolt and maneuvering into the center hole (figure 180-8.1r). A small flashlight will aid to locate the center hole.

28. Secure bolts working from collar aft to the center block.

29. Use a 5/8 in. ratchet drive and 3/4 in. socket to tighten bolts. Bolts should not be tightened over 40 ft/lbs of torque, and should look straight and uniform. Large dimples in the collar means the bolts may be too tight. Bolts can be loosened slightly to remove dimples. Work from the aft end forward to stretch the collar into place, this will help with proper bolt alignment.

30. Secure all remaining bolts.

Table 180-8.1. Collar Re-Installation (cont.)

Figure 180-8.1r. Securing Collar Blocks

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

31. Run a single piece of tape onto the lower collar edge, one inch from the edge and the full length of the collar, parallel to the masking on the lower flange (figure 180-8.1s).

Figure 180-8.1s. Lower Collar Taped Off

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

32. Inject an additional fifth tube of 3M 540 polyurethane sealant into the gap between the collar and lower flange, from the bow to the performance fin. Being sure to push the tip between the collar and the flange to ensure a good seal with the outer seam (figure 180- 8.1t).

Note 13: Material should exit the gap.

33. Smooth edge with a plastic spreader prior to applying collar seam.

35. Install the collar seam by applying one thick bead down the center of the taped off area, enveloping the metal flange edge.

This will require at least one tube of sealant.

34. Verify contact of lower flange to collar. If there is a gap, tap the lower metal flange using a five pound dead blow hammer until it is snug against the collar.

Figure 180-8.1t. Lower Flange Seal Application

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

Note 14: Ensure that the sealant overlaps the edge of the lower flange by one inch. The thickness of the sealant over the relatively sharp corner of the aluminum performance fin and flange, should be thick enough so that the corner or edge does not cut through the sealant (approximately 1/8 in. thick).

36. Smooth all excess material with a plastic spreader (figure 180- 8.1u). Ensure complete coverage between tape edges.

37. Immediately apply a second bead of 3M 540 polyurethane along the center of the first laid seam using one continuous motion.

38. Smooth all excess material with a plastic spreader in one continuous motion. Hold the spreader with two hands to create a convex shape. The seam should be 1/8 in. thick in the center tapering to 0 in. at the tape edges, resulting in a convex shape.

Figure 180-8.1u. Collar Seam Application

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

39. Immediately remove all tape by peeling tape back against itself (figure 180-8.1v), to diminish drips or sags in the new seam.

Note 15: If the lower metal flange edge is visible after applying seam, an additional coat can be applied. This can be performed as soon as the initial seam is partially set, typically six hours at 70ºF.

Figure 180-8.1v. Masking Tape Removal

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

40. View performance fin and lower collar seam (figure 180-8.1w), after seam is applied.

Figure 180-8.1w. Lower Collar Seam

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Table 180-8.1. Collar Re-Installation (cont.)

Step Action

41. Inspect performance fin leading edge (figure 180-8.1x). Apply an additional collar seam coat if metal is visible.

Figure 180-8.1x. Performance Fin Leading Edge