Bulkhead doorframe deformity

[Robert Mayer]

We have a bulkhead doorframe deformity on Osprey (our 1982 Passport 40 with Pullman berth ) which developed several years ago after rigging inspected and tuned. After noting the issue I purchased gauge to measure tensions. The forward lower and topcap had been tensioned at about 1000kg (18% breaking strength and lower aft at about 350 apparently to get mast bend. This seems above what is needed for cruising boats and I have noted comments about door not closing in Passports associated with rigging tension. The door does not close completely but had some issue at time of purchase. The doorframe as viewed from salon has 1-3 mm crack/ separation from bulkhead at top of doorframe  extending down about a foot on either side. Viewed from the berth aspect there is no overt visible separation. 

We have retensioned to topcap 700 (12% breaking strength) and lowers to 500. There has been no resolution or worsening of appearance. We replaced side chainplates this last year and saw no hole elongation, or obvious damage to tabbing or deformity of knees or cracking of deck around chainplates. A friend with engineering background  recently suggested survey to more specifically assess bulkhead doorframe which we have requested and is pending.  The bulkhead tabbing that is visible At top and bottom of lateral aspects of bulkhead by removing Chainplate knee covers and in lower compartment appear intact. 

Review of this site has a thread from 2/23/12 that suggests that such cracks are possible with rig tension but no major reconstruction was advised

The surveyor indicted removing some paneling might be needed for full evaluation. My first question is whether removing sections of teak wall paneling is worthwhile to directly visualize entire bulkhead tabbing is worthwhile or is it possible to less invasively inspect via some holes drilled and flexible scope. I have some difficulty imaging the stress forces from high shroud tension that would cause this traction effect on doorframe.

  Second- have others experienced this issue, found significant issues and what specific repairs were taken if any.

I am hoping this is a more cosmetic issue but prudent to request input from those with more experience.

Repetition of mistakes does not count as experience.

Cheers 

Bob

Osprey 1982

Blaine WA

[Malcolm Orendurff]

Hi Robert,

I have a similar issue on my 1985 Passport 40. Both the main bulkhead and head bulkhead doors are significantly misaligned.

After investigation, I discovered that the port center knee member was soaked and rotten. However, even after replacing it, the door clearance is still incorrect.

The standing rigging was replaced recently by a professional rigger at a local boatyard. I have not checked tensions since then but a survey is scheduled and I hope to know more by then.

P40 1185

Second Star (formerly Wanderbird) 

Malcolm 

PDX OR

--
--
Passport Owners Association http://passportyachts.org
To post to the group, use "reply all" or send email to Passpor...@googlegroups.com
To reply to just the author, just use "reply:
For more options, go to
http://groups.google.com/group/PassportOwners?hl=en
---
You received this message because you are subscribed to the Google Groups "Passport Owners" group.
To unsubscribe from this group and stop receiving emails from it, send an email to PassportOwner...@googlegroups.com.
To view this discussion visit https://groups.google.com/d/msgid/PassportOwners/6630fdcd-6b41-489c-8c27-953a6ac58174n%40googlegroups.com.

[Bill Schmidt]

Robert, The deformation of the bulk head may be the result of the mast step base (in keel based masts) or the deformation of the cabin top plate (for cabin top based masts). These have been problems in not a few Passport 40s.

Billy Manana

On 9/21/2025 2:16 PM, Robert Mayer wrote:

We have a bulkhead doorframe deformity on Osprey (our 1982 Passport 40 with Pullman berth ) which developed several years ago after rigging inspected and tuned. After noting the issue I purchased gauge to measure tensions. The forward lower and topcap had been tensioned at about 1000kg (18% breaking strength and lower aft at a, The deformation of the bulk head may be the result ofbout 350 apparently to get mast bend. This seems above what is needed for cruising boats and I have noted comments about door not closing in Passports associated with rigging tension. The door does not close completely but had some issue at time of purchase. The doorframe as viewed from salon has 1-3 mm crack/ separation from bulkhead at top of doorframe  extending down about a foot on either side. Viewed from the berth aspect there is no overt visible separation. 

We have retensioned to topcap 700 (12% breaking strength) and lowers to 500. There has been no resolution or worsening of appearance. We replaced side chainplates this last year and saw no hole elongation, or obvious damage to tabbing or deformity of knees or cracking of deck around chainplates. A friend with engineering background  recently suggested survey to more specifically assess bulkhead doorframe which we have requested and is pending.  The bulkhead tabbing that is visible At top and bottom of lateral aspects of bulkhead by removing Chainplate knee covers and in lower compartment appear intact. 

Review of this site has a thread from 2/23/12 that suggests that such cracks are possible with rig tension but no major reconstruction was advised

The surveyor indicted removing some paneling might be needed for full evaluation. My first question is whether removing sections of teak wall paneling is worthwhile to directly visualize entire bulkhead tabbing is worthwhile or is it possible to less invasively inspect via some holes drilled and flexible scope. I have some difficulty imaging the stress forces from high shroud tension that would cause this traction effect on doorframe.

  Second- have others experienced this issue, found significant issues and what specific repairs were taken if any.

I am hoping this is a more cosmetic issue but prudent to request input from those with more experience.

Repetition of mistakes does not count as experience.

Cheers 

Bob

Osprey 1982

Blaine WA

[Kyle L]

We have slight clearance issues with our forward cabin door as well. Our boat is a much newer (2003) 42' Passport based on the 41. Our knees and rigging are all in good shape, absolutely no known issues with the hull or deck. I believe it is due primarily to the deck being compressed upward by the rigging in addition to the tension from the main halyard and reefing lines if you are running them back to cockpit. I actually asked Bob P. why there is no deck tie down in the Passport 40' as I have seen on so many other boats. He says that because the bulkhead is so close to the mast, it is not necessary. I don't disagree-I'm sure with a properly tabbed bulkhead that deformation in the deck/hull would be minimal and not require a tiedown. But the reality is always different based on the yard/construction/fatigue/etc. It seems like such an easy solution to this common problem. I plan to install a deck tiedown at some point. Dumping halyard loads back into the mast is a much better loadpath than pulling up the deck and routing the tension back through the bulkhead. I imagine it would stiffen up the boat quite a bit.

[Kenyon Stewart]

When I had the rigging replaced here at Svendsens back in 2007, they overtightened the rig and a number of the doors wouldn't close.  I eased things off a bit and most of them were fine. In the forward head, the door does rub a bit closing and there is a gap in the woodwork there, but I'm fairly certain it was already like that.

Kenyon

To view this discussion visit https://groups.google.com/d/msgid/PassportOwners/e8623cc0-2b31-4d38-ba24-ebd4337c2d5fn%40googlegroups.com.