Hole in Etchells Aluminum Mast, with pics. Seeking advice and ideas.

GGman · #1 (**permalink**) 10-02-2007

Hi fellow sailors how are you, just looking for some input and advice. I have an Etchells and another boat, out of control, hit my boat and slid up on the deck punching a hole roughly 1.5 inches diameter in my aluminum mast just below where the boom attaches to the mast. There is a small indentation about 1/2 inch around the perimiter of the hole and no other apparent damage to the mast or boat upon close inspection. The Etchells mast is anchored below deck for those unfamiliar. I'm curious if there is a possibility of this being repaired while still keeping the integrity of the mast suitable to sail. I have some great pics available of the damage and links to these pics are below. If you have any suggestions or advice I would be grateful.
Thank you in advance, GGman.

hazmat17 · #2 (**permalink**) 10-02-2007

First I'd have a pro look at the fiberglass where the mast is supported as well as the standing rigging - a hit hard enough to do that to the mast could have injured the rest of the boat.

I suppose you could rivet a boot of some sort around the exterior of the mast w/ a backing plate behind it. The problem is that aluminum soft enough to easily shape into the profile required, isn't all that strong (sheet metal vs. extruded structural (what the mast is made of)). You could get a machine shop to fabricate the boot out of stronger metal, but you may be spending big bucks by the time you "engineer" it and get it made (CNC machine). Talk to a rigger, I'm sure they've come across this problem already.

Assuming the other boat is paying, the most conservative approach would be a new mast.

EDIT - Welding can weaken the structure if not done properly. If you go that route, use an engineer familiar with spars to design the fix & a certified welder to perform the operation. Definitely not something for Jim Bob to do at the local auto body shop.

sailingdog · #3 (**permalink**) 10-02-2007

You should be able to repair that fairly easily by having them make a reinforcing sleeve for that section of the mast, and then riveting the reinforcing sleeve over the mast.

Possible damage to other parts of the rig or where the mast steps on the deck are issues, and you'll probably want a rigger or surveyor to take a look to make sure that the hole is the only real damage.

GGman · #4 (**permalink**) 10-02-2007

There's no other damage from the hit and the mast step is below deck over the keel. Had a good look and all looks perfect. The hit was not that hard and since Etchells masts are thin it would not take much force to punch a hole in it.

sailingdog · #5 (**permalink**) 10-02-2007

Rivet a reinforcing sleeve over the area. Probably going to need to remove some of the hardware to get a sleeve of the appropriate length...and if you're really paranoid... you could epoxy and rivet the reinforcing sleeve to the mast.

hazmat17 · #6 (**permalink**) 10-02-2007

Quote:

Originally Posted by sailingdog

Rivet a reinforcing sleeve over the area. Probably going to need to remove some of the hardware to get a sleeve of the appropriate length...and if you're really paranoid... you could epoxy and rivet the reinforcing sleeve to the mast.

Forgot about epoxy - check out this stuff google "lord fusor adhesive" (Can't post links yet, not enough post count)

A company I used to work for used this in construction of ambulances - the bond is stonger than the base metal (6061-T6 aluminum)

adhesives are all about surface prep, so follow the directions.

Tartan34C · #7 (**permalink**) 10-02-2007

New mast is the best fix.
All the best,
Robert Gainer

7Psych · #8 (**permalink**) 10-02-2007

How much for a new tube? Considering you can salvage all other parts, why mess with a weakened spar? It would be something I would always be thinking about, especially in heavy air, will this mast buckle??? At the very least, I would purchase a new mast tube and re-rig it myself!

sailingdog · #9 (**permalink**) 10-02-2007

A new mast is generally the best way to go... I guess it depend on whose wallet the repair is coming out of....

Sailormann · #10 (**permalink**) 10-02-2007

Hate to sound negative here but...

I wouldn't mess around with trying to repair your mast - particularly that close to the deck and underneath the gooseneck. All of the lateral force from your main is going to be working to compress that side. The mast will break.