Building a mast step

[Krogensailor]

I have a Krogen 38. It has a very hefty mast step that unfortunately is half corroded away. I'm thinking of making a copy out of glass and epoxy. As I said its a solid 1 1/4" thick aluminum piece. What about just layering layer after layer of glass to the appropriate thickness. I'm pretty sure it would take the compression, and it would be the end of corrosion. Might be some grounding issues. Any input would be appreciated. Thanks

[onestepcsy37]

i don't think that any amount of glass could take the compression AND the mast working on it. i'll bet you could go to any good metal shop and get them to make up a new mast step to your specs.

or you might build your own out of five 1/4" aluminum plate.

[skipmac]

I had to replace my mast step plus raise it 3" due to the corroded end of the mast itself I had to remove. Used 3" thick block of UHMWPE for the base and an 1 1/2" piece to make the socket for the mast to sit in. I did put a 1/4" sheet of 6061 Al under the mast to take the abrasion as I wasn't sure the plastic would take that well.

Haven't stepped the mast yet so ask me in a couple of years how it worked.

[Cavalier]

A typical (well laid up) FG with resin will have a compressive strength approaching 20000psi. A good grade Aluminum, however, will be closer to 45000psi.

The aluminum will exhibit a much greater isotropy than you'll manage with a FG fabrication - so i'd personally go for 3.5x to 4x the cross sectional area of the existing aluminum step if I was to build one out of GF.

As previously mentioned, it may actually be more cost effective to replace the existing step section with good aluminum based on the same design.. 6061 T6 would work fine.

[bobconnie]

Stainless maybe ??? I would at least think about it!

[Delfin]

Originally Posted by bobconnie

Stainless maybe ??? I would at least think about it!

That is what I built mine out of. Here is the drawing I provided the fabricator. We polished it to 3000 grit, so its purty as well. I can post a picture if it would be helpful.

[delmarrey]

Why not just buy a new one from the manufacturer?

[Krogensailor]

Thanks for the response's. The numbers don't look to good, 20000 vs 45000. I have 10 roll's of glass here and I barrel of west system. So trying to use whats on hand. But I think it doe's make sense to fab one out of good alum. Question on that, this thing has the base and then a tenon, socket, chunk, that goes into the mast base. Do you guys think it could be attached with a couple 1" dowels? As to getting one from the manufacture, they haven't built the boat since 1990. It's the only sail boat Kadey Krogen made. They did a good job. This thing is bullet proof, but the gods do have their way with taking things back, corrosion,rot,disintegration, Give's us thing's to do

[Paul L]

You purchase G-10 frp sheets in many thicknesses.

[salticrak]

Check out the wharram catamaran sites, all the mast steps, tabernacles are ply/FG on the bigger cats. I would go with aluminum in your case though.

[Cotemar]

SS base plate to replace the corroded aluminum one is the way to go.
The new SS base plate will last the life of the boat.

My dock buddy just did his last year on a Tartan 46 sailboat.
Polished SS Looks better than aluminum also.

[Krogensailor]

Gonna go with aluminum plate . The step is not visible from the cabin.

[Paul L]

FYI, here's mast step built of using G10 on a 44 footer

[delmarrey]

Not sure if the OP is talking about a keel stepped or deck stepped, but here's what happens to alum. on a keel stepped SS plate.

And the last picture is what it should look like, like Paul L's.


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