I have some drawings of the keel and keelbox construction from the designer. The mild steel keelbox was replaced on our boat about 5 years ago and is still in good condition. The technique was similar to that described by Johnathan. Let me know if you need the drawings.
Last year, we replaced the nylon keel roller which had been jammed for several years. It was relatively straightforward to do by cutting out the old roller and fitting a slightly shorter roller (reduced cylindrical length) on a stainless insert which was screwed up to tapped holes in the mild steel shoe at the base of the keel case. This leaves a stainless flange exposed under the boat which would perhaps upset a racing purist due to the microscopic increase in drag. However it is relatively easy to do and I will probably fair it in next year. I would be delighted to provide more details if needed. I could not see any way to remove and replace the existing roller.
I would be most interested in details of all TS240s to add to the informal database that I am maintaining eg hull number, boat name, home port, contact details etc. I have information on about half of them but yours are not included at the moment.
