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post #9 of Old 02-22-2012
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On a 23' boat it will be a toss up as to the price of a new/used blank or the repair. you need to check the rest of the mast to see if it worth repairing. I have repaired masts with this problem before and everyone is a little different. this one looks like is do to corrosion cracking that started at the fastener holes. you first need to assess how much corrosion and how far you need to be away from the cracks to find metal that is full thickness. I would weld on a cover patch that is at least 7 times as long as the mast is wide above and below the spreader location. and the end of each piece needs to be tapered at least 60 degrees. the cover patch would be welded all the way around and then the spreaders would be remounted. this is the same way we repair a broken mast that has been snapped off or folded over at the spreaders. a properly supported mast has most of the load in compression and this type of repair is much stronger then the rest of the spar

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