The Saga of the Catalina 22 Motor Mount (1983 Original Hardware)

If you've followed the recent posts on this blog, you will know that we are attempting to use a Torqeedo 1003L to power our Catalina 22 sailboat, Ellipsis.  We are committed to a gasoline-free sailing experience.  Previously, we've used a Minn-Kota 50-lb thrust trolling motor to get us in and out of the marina, but we decided to throw down on a Torqeedo Travel motor to give us both greater thrust and longer potential range at moderate speeds.  We will report on the Torqeedo's performance when we are able to conduct actual sea trials with the motor.

   In the meantime, the attempt to use the motor has required us to re-examine our old, 1983-vintage motor mount (see the previous post).  After we jury-rigged a 6-inch extension to the motor mount using some scrap wood inserts, we discovered that one of the "pivot bolts" on the mount had slipped out of the various brackets needed for the motor mount to work properly (see the photos).  While this problem could normally be solved by putting a stop-nut on the end of the bolt, the bolt was so damaged that a stop-nut could not be threaded.

   The result:  we had to remove the entire motor mount assembly and attempt to rebuild the weak parts.  This post reveals key information about the original factory motor mount of a 1983 Catalina 22 sailboat.  It is possible that parts of the original hardware had been replaced, but read on to learn more.

   First off:  we are NOT interested in buying a replacement motor mount from Catalina Direct because the Torqeedo is a light-weight motor, and we do not need to "beef up" the motor mount.  All we wanted to do was to replace a single bolt on the motor mount.  Like many boat projects, this seemingly simple project has spiraled into something much more complicated.

 Here are the major issues so far (with solutions, where I've discovered them):

• The original C22 motor mount was fairly weak, and heavy outboards could actually bend the vertical support brackets of the motor mount.  Since Ellipsis has a lightweight electric trolling motor, and now the fairly lightweight Torqeedo 1003L, I used a heavy vice to straighten the bent brackets that we inherited from the previous owner.  So far, so good.  Catalina Direct offers replacement brackets, but, given the weight of our motor choices, I think the straightening with the vice will be sufficient.
• In disassembling the motor mount, I learned some new terminology when it comes to fitting together pieces of metal.  I'm drawing on the Catalina Direct website for some of these terms, and I hope they are clear enough.  According to the CD website, their $289 replacement motor mount includes the following improvements:  "1) Replace the plastic bushings with bronze for long life. 2) Add compression sleeves to each pivot bolt so the bolts can be tightened without squeezing the parts together causing friction."  Turns out that my old motor mount has "plastic bushings," which are still viable, but the "compression sleeves" are a problem.

Check out the photos.  I turns out that the "compression sleeves" (basically, metal tubes with an inner diameter matching the through-bolts) were apparently made of aluminum, and mine seem to have been irreparably corroded (again see the pictures).  So, in order to get the Torqeedo tested on Ellipsis, we need to repair the motor mount--with a 6-inch extension.  All of this is doable, but it is taking FAR more effort than we anticipated, along with the accompanying expense.  As they say....  BOAT stands for "Break Out Another Thousand....."  Be warned....   (See photos below)