[alberg30] mast-step repair

[Joe Tokarz]

From: alberg30 at interactive.net (Joe Tokarz)

Hello everyone-- I hope you got alot closer to the water than I did my
Memorial Day Weekend. We began the project of repairing our compressed
mast-step on #499. I have consulted several articles on the mast-step
repair and Fiberglas work but now I have a few questions for the group.

1) After removing the core and outer fiberglass layer in a 2x2 foot area,
when I replace the core do I need to use something other than solid
fiberglass? Provided I can lay up that much fiberglass, is there any
disadvantage to not using another coring material? other than cost +time?

2) After removing the mast-step plate I noticed that the six screws in this
plate are screwed into the deck. How are they held there, were they screwed
into fresh fiberglass? What kind of holding strength is that? I literally
peeled the plate off with the screws still attached using a screwdriver as
a pry bar. Has anyone ever thru bolted the mast-plate thru the deck? What
do you think about that? Or maybe glassing the bolts in upside down so they
can have nuts screwed on them topsides?(I think Scott Murry "Bill of
Rites"did this.) What should I do?

3) FYI: water leaked into the core thru the six bolts in the mast-step
plate, and through the bolts for the hinges for the forward hatch. If I had
rebedded these when I first got the boat in 1996 I probably could have
prevented the majority of the damage. Removing and resteping the mast
several times aggravated the problem. You might want to check your if you
just acquired your boat.

3)FYI: serious compression at the mast-step prompted us to make this
repair--namely the cabin doors down below would not swing open since the
deck was sinking. Cutting through this mess was a nightmare, I cant imagine
this thing failing as it was in my lifetime. The mast-step area was fully
1/4"fiberglass, then maybe 3/8" balsa core, then more glass and the liner.
There was no delamination, just compressed core in an actually small area
maybe 12x9". I might sail the hell out of the boat before I ever attempted
this repair again. I dont think it'd break. PS-Everytime I go at this thing
(the boat) with a router or circular saw/drill I walk away amazed at what
strength this thing has. Gotta love them older boats. My craftsman tools
sure don't.

I have some jpg files of photos from this weekend if your interested.

Thanks in advance;

Joe #499
One Less Traveled"

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