Seeing some recent discussion on removal/reinstallation of big bronze stern tube cutless bearing housing on TY 37, I am attaching a series of pictures of Starlight Dancer, TY37 Ketch # 424, that follow the alphabetic file sequence. I have no time right now to explain everything, there is an email long time ago with some of the same pictures. Basically, my challenge was to find a replacement blank that could be machined to the bolt holes, stern tube and cutless bearing to fit. The crooked Panama machine shop sold mine to another TY37 passing through the Panama Canal and it took me 1-1/2 year to find the replacement part.
	
A, CBH removed, therefore threaded studs backed out with their double nuts

B, Close-up showing the shaft log tube with male end threaded and cavity around it to allow the female stub-out of the new casting to be inserted

C. Accurate template; the bolt pattern was not even. Used a dummy shaft insert to center template

D. New blank, stub machined on outside to fit

E. View into blank after machining and "heat fit" new sleeve to match cutless bering OD. Sleeve was machined to fit shaft that I had "skimmed off" from 1-1/4 iinch (31.75 MM) to metric 0.00 mm to make sure surface pitting were ne cracks; standard cutless bearings available for that diameter.

F. Screwed new big bearing housing onto Stainless steel shaft log; actually, no thread in new casting but overly tight fit; SS tube cuts light thread in casting; (some TY37s had the yard erroneously cut through the studs not knowing that they had to be backed-out to get the casting off; and did/could not replace those. So owner, not knowing better relied on shaft log and M5200. I purposely over-ground the rear end of the marred keel to create 3/8 to 1/2 inch gap between it and the flange. The blue tape around it was to form a casting barrier for epoxy

G. New epoxy mating surface, beautiful if I may say so myself; broke loose the bolts, twisting them for 1/2 hour so not to cast them solid 

H. Final product, shaft turns fine. Notice set screws for cutless bearing and port holes to catch water for lubrication and cooling.

J. Stuffing box, ground off flange with broken stud, cleaned inside, outside. Polished inside off existing s.t. 
box with a cylindrical drill mounted sander with tight fit (using sticky back sand paper from a roll).

K. Epoxy fit another threaded bronze tube with hose connection on the other side into that; drilled and tapped for two  set screws at 10 and 2 O'clock. Note, holding tank top cut away for different tank insertion. 

L. A short heavy wall hose with a new mounted stuffing box, purchased from Buck Algoin (?) is double hose will be clamped to the tub like a PSS tube. The hose will give some flexibility to minor alignment issues. Unfortunately no close up pictures of end result.

Hope attachments (compressed) are not too large for email and hope this provides some ideas to deal with our lovely TY37 shaft and tube problems.

Hans G/J. Kosten