Corrosion and pitting were discovered on the aluminum tie-rod hangers on this Bristol 45.5. After 20+ years and some leaky chainplates galvanic corrosion was heavily taking its course. We agreed with the owner that new pieces in 316 SS would be more expensive but worth it for a lifetime fitment. We saw the job through from consulting, part design, prototype, final manufacture and fitment.

Prototype hangers made to check angle fitment. Original parts were bored at angle and mismatched by 2-3 degrees causing uneven loading of stemball and binding at the fitting exit. A cup washer was incorporated to the D1 cap to improve seat and angle throw.

Nitronic U-Bolts polished and NDT’d before re-installation.

Changing part design to provide adequate cross sectional material where needed.

Final design parts milled on 5-axis CNC.

Original pieces with heavy pitting. After initial examination and measuring the V1 cap seat was found to be within a mm from punching through to the counterbores.

Installed and in use. A slotted style approach was taken to allow for proper seating of the rod head. The deck and rod are out of tram both on x and y axis. The cap-tang style slot allows for the heavy athwartship angle and a reverse taper allows for the smaller fore and aft angle.