Pitting and corrosion before repair
Belzona applied over repair
While performing routine maintenance on a 110 foot Broward yacht’s Maxwell anchor windlass, we did a full tear-down and inspection. When we disassembled the Maxwell windlass, we found excess/severe pitting and corrosion in the cover body. Most marine aluminum equipment suffers from this type of corrosion over time. Unfortunately the part was so old that Maxwell did not have replacement parts readily available. The part was cast and very complicated so machining a replacement part was not feasible or economical.
In order to remedy the situation, we used a product call Belzona. It is a 2-part repair composite for metal repair and resurfacing based on solvent free epoxy resin reinforced with silicon steel alloy. This repair material will not corrode and resists a wide range of chemicals. It is easy to mix and apply without the need of specialist tools and can be machined using conventional tools.
The part was first sandblasted clean and prepped. We apply the Belzona to the repair area on the Maxwell windlass similar to applying frosting to a cake. Once it cures the material machines like aluminum. We then put the unit in the lathe where the cutting tool cuts the ID (inside diameter) of the windlass part. What we are showing in the accompanying pictures is the process half completed so what you are seeing is a smooth round surface under and to the left of the cutter and the frosting mix that is about to be cut to the right of the cutter.
Unit in the lathe where the cutting tool cuts the ID (inside diameter)
The final step in the process is powder coating before re-installation back onto the vessel. With this type of repair, the owner should expect many more years of use of this Maxwell windlass.