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Old 06-02-2012
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Aluminium mast damage/repair

Looking for some input and advise on damage done to a keel stepped aluminum mast. The boat was damaged in the tsunami last year and in the hast of getting her rigging removed and the boat hauled out of the water the owner did a number on the mast by using a sawzall to cut the mast free from the seal where the mast passed through the cabin top. There are gouges in the mast from the saw blade all they way around the mast. Most are fairly superficial but a few of the gouges cut about half way through the aluminum.

I don't know much about aluminum and it's integrity. I am wondering what kind of repair could/should be done. How concerned should I be about structural issue of the mast as is? Unfortunately the yard where it is currently sitting does not have much knowledge in this area. Any recommendation on repair facilities in the Pacific Northwest would also be appreciated?

Attached are the pictures of the gouging.
https://picasaweb.google.com/1167699...9366/June22012

Thanks you for any advise or input.
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Old 06-02-2012
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Re: Aluminium mast damage/repair

I'm not a metallurgist.
Most of the damage I see in your pics looks superficial.
The mast has to stand up to compression loads.

I'm not sure if you should have the newly exposed aluminum anodized but likely a good idea. I'd also guess that with some marine epoxy and cloth you could build up a collar over the damaged area.

What kind of boat is it?

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Old 06-02-2012
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Re: Aluminium mast damage/repair

Don't cover it up with epoxy, that will allow moisture to do even more damage over time. You should have the mast sleeved for a best result.
Wow, a sawsall, people never cease to amaze me with the things they do.
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Old 06-02-2012
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Re: Aluminium mast damage/repair

Sleeve it or replace it are the only two options. Any gouges that go deep into the metal at a minimum will create major stress risers, and will cause the mast to fail when it's stressed.
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Old 06-02-2012
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Re: Aluminium mast damage/repair

Do nothing radical, Here's what I'd do. Wrap it in wax paper tightly. Split a large piece of PVC pipe to go around it over the wax paper with maybe 3/8" clearance. At bottom of PVC, cover the gap with duct tape. Fill the annular space with epoxy and allow to set.
Carefully use a hacksaw to slit the epoxy inside where the PVC is slit. The wax paper is your release layer. You now have a mold of your mast in two halves. Use huge SS hose clamps to hold it around your mast. You can remove it whenever you like for inspection but I'd seal the top around the mast with silicone seal.
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Old 06-03-2012
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Re: Aluminium mast damage/repair

Quote:
Originally Posted by Frogwatch View Post
Do nothing radical, Here's what I'd do. Wrap it in wax paper tightly. Split a large piece of PVC pipe to go around it over the wax paper with maybe 3/8" clearance. At bottom of PVC, cover the gap with duct tape. Fill the annular space with epoxy and allow to set.
Carefully use a hacksaw to slit the epoxy inside where the PVC is slit. The wax paper is your release layer. You now have a mold of your mast in two halves. Use huge SS hose clamps to hold it around your mast. You can remove it whenever you like for inspection but I'd seal the top around the mast with silicone seal.
While your at it pray to fairys to keep your mast up. About as effective.
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Old 06-03-2012
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Re: Aluminium mast damage/repair

PNW... Call CSR in Seattle.
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Old 06-03-2012
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Re: Aluminium mast damage/repair

I'd probably get section of mast and sleeve it. That's a bad place to screw around with a cosmetic fix.
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Re: Aluminium mast damage/repair

CableB - The boat is a Tashiba 31. Beautiful boat in great shape other then the hack job on the mast.

Puddinlegs - Thanks for the reference, I'll look em up.
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Old 06-03-2012
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Re: Aluminium mast damage/repair

Quote:
You now have a mold of your mast in two halves. Use huge SS hose clamps to hold it around your mast.
Stumble is right. This suggestion will have no benefit because:
1. The epoxy "sleeve" has no strength because there is no reinforcing material like roving or carbon fibre.
2. The "sleeve" is split which is an inherent weak point.

I highly recommend consulting a professional rigger and refrain from DIY in this case. Most DIY solutions will look good but have no structural benefit.
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