Condolences
Hello,
Oh, how I hate those frozen sleeves. I am sure that dealing with that thing was a nightmare; what form of explosive device did you use to remove it?
As for the new pin I would recommend... a sleeve. You could build a 1.3" rod, and it would likely have a strength of well over 100,000lbs, but what's the point? The idea is that any shear loads on the mast wall should be transferred to a maximum number of aluminum molecules, to prevent deformation; hence the oversize pin. It has nothing to do with required bolt strength. So sleeving a smaller pin is actually a fine option, if you isolate the metals with Tef-Gel. Better yet, consider shouldered bushings and a lathe-cut nut thread, so no one can overcompress the bolt and thus the mast.
Glad to hear that you are working to get the load to the deck via that wedge, though of course much of it will be borne by the bolt.
Fair leads,
Brion Toss
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