There is more than enough space in the void above the keel to put in the removed ballast, cut or cast into small pieces. This would only raise the CG of the ballast about 5" above original. Cutting the large lump of lead into small pieces would be quite laborious, with quite a lot of wastage - although cuttings could be melted down and reused.
Alternatively, I have found a foundry in Barcelona
who will recast the spare lead into ingots, or 2 bulbs to bolt onto the existing keel, or cast the whole amount (about 1,450 kg) as a new bulbous, shallower keel.
Then, with the mast stepped in the new tabernacle, she could sail the canals or the sea
The mast was originally keel stepped, but I have already cut it off at deck level, placed the offcut in the step, reinforced where it meets the deck, glassed it in, fitted a teak pad, and a stainless steel tabernacle.
The mast just need the appropriate holes drilling for the necessary pivot and support pins.
I just checked the prices I got from the foundry last October.
The cost to cast the offcut lead into ingots for placing in the void space is €500. This is probably the best option, as I could take the lead to the foundry in my trailer and leave the trailer there to collect when ready.
To cast the offcut into 2 bulbs to bolt on the sides of the keel is €2,800. This would necessitate making a mould of each side of the keel for the founder to work from.
To completely recast the keel as a bulbous one would be complicated and very expensive, probably around €7,000.
There is still 10" of ballast keel left in place, more than half the original 3,200 lbs. She rolled interestingly in a 3 foot or so beam sea with the mast laid on deck
when I brought her down the coast from the yard where I did the keel work, but she is quite stable, especially now the mast is ashore.
She was valued at €31,100 (~£27,000) at her last survey
, in May 2010, I would sell her for £10,000.
Any less than that and I might as well sell off her equipment
first - the Alpes Inox cooker cost over £2000, just for starters. I owned a marine
engineering business in Spain
- air conditioning
, domestic and generators mainly, so bought everything through the business from the companies we represented.
There is a full set of sails including a new roller genoa (I sold the reefing gear for it), and there are spares on board for just about everything - new engine water pumps, etc. etc., as I planned to do some serious cruising when I retired.
Pics here http://s857.photobucket.com/user/nomoss
Edit: The deck is suffering from exposure to the sun and weather, and needs sanding down and repainting. The topsides are acceptable. The hull is painted with Coppercoat. The black antifouled part of the keel in the picture on the travelift is the solid lead part of the keel (glassed in). The keel above that is hollow, where I planned to put the lead inside.