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  #11  
Old 03-29-2010
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Now it sounds like you have a bunch of holes, "like a shotgun blast", not just one or two. That makes me think you may be seeing where a winch or cleat was mounted, and then replaced with a new winch or cleat with different fastener spacings. In a boat that size, the mess of holes probably won't make any difference. (Of course the minute you post a picture showing a gaping trench of corroded aluminum, I'll take that back.) It's not likely to fall down soon. You can fill in the holes with an epoxy/fiber mix and then paint over it if you're worried about structural integrity or cosmetics.
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Old 03-29-2010
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Stillraining:
As far as I could tell, none of them were tapped. I didn't stick my finger in any of them though...

Paulk:
Yes sir, there are a bunch of holes. Structural integrity is EXACTLY what I am worried about. With this being my first "big boat," and while at times sailing with an inexperienced crew (a local youth group) the LAST thing I want is for the mast to come down on top of someone. I am intrigued about your epoxy/fiber mix. I am unfamiliar with this. Do tell me more...

Everyone:
I have thought about ways to repair it. I am a welder, and can weld aluminum. I however DO NOT think this is a good idea, as I believe the heat affected zone will weaken the spar. From what I know the spars are heat treated after they are pulled from the rolls. There is no way, after welding, I could reproduce this heat treatment to maintain its original strength.

I have also thought about placing a matching shaped sleeve inside or outside the lower section of the mast and riveting the two together to increase the strength.

Given that none of you have yet seen these holes (he was supposed to get me a photo today, but didn't), is this something that I should even be worried about?
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  #13  
Old 03-29-2010
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Yes, welding the mast would be a big mistake. Filling the holes with JBWeld or thickened epoxy might mitigate their existence a good deal.
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  #14  
Old 03-30-2010
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I have discovered the cause of the holes, and they are in fact not drilled at all. I went back by today and saw the mast in better light. The boat is stored indoors, and the foot of the mast was in the corner of the building where it was not very bright. Today, I got it in some light to snap some pictures and found the holes were not as smooth as I thought.

It seems as though this mast at one time had an unfortunate meeting with slag from a cutting torch. As the torch cut the slag and it fell/blew off, the molten metal was more than enough to melt right through the mast puncturing it in several places.

The damage was mostly constrained to the forward part of the starboard side of the mast. There was at least one hairline crack between two of the holes, several spots of surface damage, and, had I been able to see inside or run my hand inside, I would have expected to see scarring on the inside of the mast opposite the holes.

I guess the question is this: is this mast dangerous?

I know there is a heat affected zone that would be similar to welding where the hot metal went through, but, I would guess it to be quite a bit smaller. When I realized what it was, it made my stomach turn. It raised some red flags for me, and I hate that cause the rest of the boat is in pretty good shape for the price, and it has a nice trailer.

Should I stay away from the boat? If I decided to go ahead and get it, would it be very hard to find a replacement mast that measures 26' 10" like this one did?

I am open to any advice. Please advise.





Thanks guys.
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Old 03-30-2010
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Run.
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Old 03-30-2010
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and once you are running like jones said run farther and faster

unless they want to buy you a new mast, i would bet this is the reason the boat is for sale
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What would a replacement mast run for a boat of that size?

And yes, I think you are probably right about this being the reason this boat is for sale.
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Old 03-30-2010
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Run as posted or get a professional to sleeve it in the affected area and beyond a ways. Sleeving internally is commonly done on masts that are built from 2 separate extrusions, usually near the spreaders.
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Old 03-30-2010
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Metalworking merit badge, maybe? lol
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Old 03-30-2010
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I would be hesitant to sleeve that mast because of the size of the damaged area and the location of the damage. It is an uncommon boat, so finding a used mast might be tough. a new one won't be cheap, but you might be able to adapt a mast from a more common production boat of the same approximate size, such as a catalina 22 or a Tanzer 22, but then you have a further project, altering rigging and possibly sails, and the boat is no longer a good deal. there are better choices out there.
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