When we crossed the Atlantic in 2017 on our way to the North Sea, we encountered some strong winds that caused some damage to our starboard side deck and chain plate. GG sourced some stainless plate in Cork and spent some time re-glassing the broken fiberglass and then installed the 5 mm thick plate as backing plates for the chain plates and side deck cleat. With fiberglass bonding to the deck and knee braces this repair seemed pretty strong.
Until this season of sailing when we noticed that the starboard deck around the lower aft shroud attachment was bulging a bit. Upon further examination, once the interior furniture was removed to allow access, we discovered that the fiberglass repair had broken completely through. Not delaminated, not fractured - it actually broke right through the six layers of 10 ounce woven fiberglass. What loads are being transferred through that shroud to cause such damage? It's incredible. Even the backing plate was bent upwards.
As an attempt to repair the broken chain plate GG drew up a template using a cardboard box from some cookies on board and went in search of a machine shop. We had heard that there was a fishing port in Monastir and that is always a good place to start looking for repairs to a boat. The port is 2 km south of the marina so we walked over there one morning to see what was available. It was a grimy, busy place, full of fish boats of all sizes with catches being unloaded into ice hoppers and nets strewn across the road being repaired. There is the most enormous travel lift we've ever seen that can handle boats to 250 tons; that is really massive. And in a corner of the yard is a marine chandler complete with stainless fasteners, bronze through hulls, paint, caulking and most items to be expected to fix a boat. Across the road was a metal shop with an incredible selection of flat bar and tubing in steel and stainless (in-ox). GG selected a piece of 8 mm thick stainless that was nearly 2" wide that could work for his envisioned repair. While talking with the metal shop owner, a metal fabricator came into the shop for a piece of metal. He spoke perfect English and in no time at all said he would bend the flat bar to the shape needed and drill holes in the required locations.
For less than $50 GG had a substantial piece of stainless bar that was hopefully going to firmly connect the base of the chain plate bracket to the knee brace attached to the hull. The hull will pull apart before that bracket breaks. But still, why is this happening to that one shroud attachment when none of the other seven shrouds and chain plates have shown any sign of movement. It's a mystery and one that needs to be figured out sooon.