[alberg30] mast-step repair

[Miabarchet at aol.com]

From: Miabarchet at aol.com

JOE:   I had a similar problem of a wet core caused the bolts for the forward 
hatch hinges and a hole through the deck for the mast wiring. the damp area 
was apprx. 1 sq. ft.. I removed the wet core with some tools I made up 
resembeling long thin screwdrivers with the tip bent down 90 Deg. and 
sharpened. I opened the deck under the hinge plates and I opened the wiring 
hole to about 1 1/2 '' Dia. This allowed greater access to the core. After 
pulling out all the damp core until I reached solid  I used the tool to 
scrape the uppper and lower surfaces of the deck clean. After  further drying 
 with a heat gun I filled the entire area with West epoxy , high density 
filler and chopped fiberglass mat. I also epoxied stainless steel back up 
plates under the hinge area on the liner and redrilled for the hinge bolts 
(now thru solid glass & epoxy) . The hinges covered the deck opening 
completely hiding the repair. Better than new. For the wiring hole I epoxied 
in a 1/2'' ID. bronze pipe (nipple) with a 1 1/2'' flange to cover the 
damaged area. The nipple extends approx. 3/4'' above the deck with male 
threads.When I store for the winter I remove the wires and screw on a cap.

This was about 7 years ago and I haven't had a problem since. I don't recall 
If the area if the area under the mast step plate had the same problem, but I 
do recall removing the plate. I also felt the 6 machine bolts threaded into 
the fiberglass were not very strong method of attachment. Again I don't rcall 
the exact sizes - 

I made bronze threaded inserts ,5/8 -11 external threads with internal 
threads to match  the original bolts.I drilled and tapped the deck for the 
5/8 -11  inserts which were epoxied in place. 
     I hope the helps .
                                 Jim Allocco 
                                 #565 Barchetta Mia

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