Mast Step Re-fit
By Dan Pfeiffer and Graham Bryan
Solution #2
 Another solution (used on #212) is a new fiberglass mast step supported up out of the bilge on fiberglass floors (transverse beams). The new step sits about six inches higher than the OEM. To maintain the proper rig geometry, six inches is cut off the mast, including the corroded portion. A portion of the cabin sole had to be cut out to provide access to the bilge for the floor fabrication. The cut out portion was fastened back in place. The glass for the floors was laid-up with epoxy over foam forms cut to fit in the bilge at the right height for the step to sit on. One OEM floor was replaced to provide more area for epoxy bonding of the new floors. By building the floors in place the entire structure is made with primary bonds (see bonding sidebar). The mast step is made of two 7" x 14" x 1/2"-thick fiberglass plates laminated from layers of biaxial glass with mat. The lay-up was done in a jig/press made from 3/4" plywood. Care must be taken to keep this thick lay-up from overheating while it cures (read and understand the epoxy literature). The top plate is slotted to slide fore and aft on the bottom. 1/2" bolts hold it down. They go through the bottom plate into threaded holes in a stainless steel angle bracket that is bolted to the new floors. The slots and holes were made on a milling machine.
This solution has advantages over the Metalmast step replacement. There is no metal-to-metal contact to cause galvanic corrosion, the base of the mast is raised out of the wet bilge, and the new floors add stiffness to the bilge/keel area of the boat. It is more expensive then the Metalmast solution, takes more time and requires cutting a section from the cabin sole but is a lasting solution to the corrosion problem. A similar
step refit was made to “Jade” (#187).
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