Mast base epoxy repair

[Intifada]

A survey showed excess moisture and possible rotten wood where the mast sits on deck. I was thinking of replacing the timber (pictured) with a hardwood similar dimensions and then filling the rest with West System epoxy and filler of colloidal silica and/or chopped strand. Finally covering with woven glass fabric and epoxy resin.

These are the materials I have to hand so it would make life much easier if these are what I could use. Is this an acceptable solution? What amount of colloidal silica and chopped strand should I mix with the resin?

[tkeithlu]

This problem of water intrusion/rot at the mast step is a common topic on the forum. Various solutions are possible, so let's go with one that uses your materials at hand.

Let's start with your digging out all rotted wood. Stop when you hit stuff that you cannot dig out because it is hard. Then, inject epoxy until you fill the space, avoiding creating bubbles. That will be fractionally heavier than the original core. If you want to mix in chopped fiberglass, OK, that will increase strength. Mix it so that it's a paste that you can still push into that 1 cm space. Where you have no upper layer, make one out of fiberglass cloth, several layers, laid up one layer at a time. Beveling the original fiberglass will give you a stronger patch.

Your repair does not have core material at the mast, so it's permanent and no water will get in. Go sailing.

[Manateeman]

Could you take the following pictures. Straight down onto the deck about 3x3’.
Compression post top from inside. Mast deck plate.
Most of the force is in compression but not all.
Are you sure you can’t get any triaxial stitch mat.
What boat. Where are you.
The manatee crew.