Mast Splicing

[PaulM]

All,
I'm thinking of buying a project boat that was demasted just above the gooseneck. The mast suffered little damage. The standing rigging, mast wiring and spreaders will need replacing. My options for the mast are to buy a complete mast section and transfer the fittings or splice the mast. Is splicing a aluminum mast an acceptable repair?

Thanks
Paul M

[Jim Fulton]

It's not uncommon to see boats with factory masts made in two sections joined together with an internal sleeve. I don't see why it wouldn't work for a repair.

Jim Fulton

[bigwhitesofadog]

A lot depends on the construction of the mast. I looked into this in great detail when the mast was damaged at the spreaders. This mast had internal track for a spinaker car, as well as other extrusion details that made it impossible to splice. I replaced. $$$$$$$

[Matthew Sebring]

We've done may many mast splices here so far without issue. Typically we cut out the damaged material so it's square surface meeting square surface and then make up a sleeve out of pieces of used extrusion (we've got a lot of old pieces here there and everywhere) which we cut and weld up until it's as close a fit as is possible then put it in place typically with mechanical fasteners. As I said, we've done a bunch and so far there have been no failures in 20+ years of business so yes it's very doable but making up a sleeve may be tricky depending on the materials, tools, and skills you have available.

[Aqua Puttana]

Originally Posted by Matthew Sebring

We've done may many mast splices here so far without issue. Typically we cut out the damaged material so it's square surface meeting square surface and then make up a sleeve out of pieces of used extrusion (we've got a lot of old pieces here there and everywhere) which we cut and weld up until it's as close a fit as is possible then put it in place typically with mechanical fasteners. As I said, we've done a bunch and so far there have been no failures in 20+ years of business so yes it's very doable but making up a sleeve may be tricky depending on the materials, tools, and skills you have available.

Unfortunately I now have an original 1985 J/22 mast that is twisted at the bottom and a new in April 2008 mast broken at the topping lift exit box. I'm thinking of making one good cruising mast between the two carcasses. How long do you think the fabricated internal sleeve should be for this repair? Thanks in advance.

[Douglas]

Currently, I too am involved in a mast splicing project on a 45' Forespar 4 1/2" X 7" extruded aluminum mast tube.

Please check the archive on this forum, as this thread is already covered.

The actual extruded aluminum mast tube, is quite inexpensive, like usd $ 600.00 for my 45' tube, but after a spar builder starts work on it,,,, look out , because those $$$$$$$ signs you describe become evident, rather quickly.

On my rig, the two stb spreaders were forced fwd, the welded-on bases gave way, and they dimpled the mast wall, resulting in a set bow or bend in the mast, as viewed from end to end.

I found out later that the Forespar technique of welding the spreader bases onto the mast wall, destroyed the temper of that mast wall, making it weakened where it shouldn't have been allowed.

I would suggest that it is less expensive and quicker to repair a damaged rig, than to completely replace it, if you are considering, buying a new one.

I was given some supposedly expert advice from the most expensive yacht repair yard here in Singapore, they were supposed to have knowledge about these type of rigging repairs, but it was all talk, that was confirmed later,,, as bogus .

I was also very surprised to find out that aluminum spreader extrusion prices in the US, are sky high too. Like usd $ 118.00 per 3', and that was a year or two ago.

My final conclusion is do everything you can to keep your existing rig in " good nick" , as the Kiwi's say ,,,, because, with out it, you go nowhere, fast !

Douglas

[on the hunt]

Douglas

I am newby and a crew that was delivering my boat to Australia lost a forestay and the mast came down not far from Singapore. The quote to by a new mast from Zspars and get it delivered is around $15K Singapore. The price to sleeve and repair is $2K but Raffles marina wont let them work at the marina and the cost to remove the mast and transport 10 minutes up the road is $5800 SGD. Any advice on alterantives for a stranded sailor in Singpaore would be much appreciated

[Brion Toss]

Hello,
Let me get this straight: they won't let you have the mast repaired in their yard, and transport costs about as much as a good used car... Were the deliverers insured? Can someone in the yard do the work? Can you do the work in the yard? Where is the break? Any other damage?
Fair leads,
Brion Toss

[Douglas]

Ahoy Newbe , I replaced my Forespar 45' X 4" X 7.5" aluminum mast here in Singapore, and that was at Raffles where Jeffrey Leng is the yard master, in February 2011.

The reply I had received from my query to Forespar was unfortunate. At that time 2005 , Forespar was way overbooked and said it would be a que of over 8 months, before they even could build me a new mast, not to mention the shipping time and then moving it to the boatyard .

This forum was a God Send for me. I received enough info here to give me the confidence to build a complete new mast and all it's fittings , D I Y .

Yes the S'pore prices are a shock. I think that yard charged me SD$ 600.00 to mobilize a crane for one hour work to remove the old mast and install the new one.