Cracks in Mast w/ Photos
 

Brion - I have a 1981 Morgan 382 with a Kenyon mast. I'm preparing the boat for offshore cruising - first to the Caribbean. After that, we'll see. I pulled the mast to replace the standing rigging and found two cracks at the compression sleeves for both the lower and upper shrouds. Aside from these two cracks, the rest of the mast seems to be in pretty good condition. There is some corrosion on the masthead welds, but it looks minor. Obviously, I cannot see what is going on inside the mast. A few inches above the lower shrouds are the spreaders. A few inches above the spreaders is an original sleeved seam. Are cracks like these repairable? Welding?

Here are some photos of both cracks:
https://www.dropbox.com/sh/14zgxr64s...7tqKU-wHa?dl=0

https://www.dropbox.com/s/seo0h21sgh...hroud.JPG?dl=0

Hmm... not sure what to make of this. I've spoken with a few different spar repair places, and I've received a few different opinions ranging from re-welding the compression sleeve to doing nothing.

The "do nothing" opinion was based upon their experience that many compression tubes are never welded to begin with; the mast is simply drilled and a free-floating sleeve is inserted. The sleeve's only function is to protect the mast from being crushed by the rigging bolt. They suggested that the mast is fine, it's only the sleeve weld that is failing. Even if it were to continue to crack around the circumference of the hole, nothing bad would happen. I would just have a free-floating sleeve. They did not think that the crack would continue through the mast - only the weld.

The second opinion about re-welding was couched in the following reasons:

1. if the weld fails, the compression sleeve will no longer protect the mast (I'm not sure I buy this, the sleeve is still in the mast and cannot compress)

2. if the weld fails, the mast might buckle

(it should be noted that the guy specifically told me that he is desperate for work in the winter)

Welding concerns me in that it can weaken the mast even further by undoing the tempering. Installing a doubler also involves welding. Riveting a plate involves inserting a dissimilar metal rivet into the mast exacerbating corrosion.

Both solutions seem like they could make the problem worse. Either a weakened spar via heat or the crack continuing to spread.

Options
 

Hi,
Welding is a truly lousy option here, as it is very difficult to do without making things worse, is unlikely to make things better, and it will in any event destroy your paint job. The shape of the cracks indicates that the tube is indeed welded in. These cracks are very likely to continue to migrate into the mast wall, at the location on the mast where the standing rig loads are highest. I would drill out for shouldered bushings, and get compatible tangs for them. This will eliminate the fractured metal, and give a fuller bearing for the throughbolt.Said throughbolt will have its threads cut on a lathe, with nuts at both ends,such that the threads stop just outside of the tangs, thus no compression on the mast.
Fair leads,
Brion Toss

Thank you, Brion! Can you recommend a shop in the Annapolis/Solomons, MD area? I've called three and they all want to weld or ignore.

Possibility
 

Hi again,
I've put a feeler out, will likely hear back on Monday.Stand by.
Fair leads,
Brion Toss

Thanks a million, Brion!

Hi, Brion. Have you received any replies to your "feeler"? Again, I appreciate the help!

Also, I'm about to order your book, The Rigger's Apprentice. However, the word on the street is that there is a new one about to come out. Is that rumor true? If so, when? I may wait to order.

Not sure if Brion has an answer yet, but John at Eastport Spar and Rigging may be able to help:

http://www.eastportrigging.com

Thanks, Don. I've actually spoken with John about these repairs - he is insistent upon welding the compression tubes.

Success
 

Hi again,
I just heard back from Steve Madden, at Madden Rigging (http://www.maddenrigging.com/). He's been out on a delivery, as well as attending a Selden workshop. So there's a good start; riggers into actual sailing, as well as ongoing education tend to be much better than ones who aren't. He agreed that welding is a bad idea, and has the sources for the appropriate bushings, and I urge you to go speak with him. Let us know how it all comes out.
Fair leads,
Brion Toss

Brion - Thanks a million for your help on this. I've called and left a message for Steve. I'll certainly report back about how this turns out.

Thanks again!

Steve Madden
 

Brion - Thank you so much for the recommendation. Steve is a great guy and may be one of the most helpful gents that I've met on this refit adventure. In fact, he was the only guy willing to take a look in person.

He assessed the mast and suggests that I install a stainless steel "doughnut" around the compression post sleeves. Drilled to size the through-bolt and then epoxied and riveted to the mast. A different recommendation that the flanged bushing, but better than welding.

Sound reasonable?

Lovely
 

Hi again,
I am so happy that things are going well there. Steve's solution sounds fine -- same principle. And note that you do not need a compression post, assuming the threads stop where they should, and that the bushing is thick enough.
Fair leads,
Brion Toss