tophatyachts.com

To avoid hijacking a different thread I thought I would start my own.

My position is problematic. The original step is in pretty bad condition, but it is repairable. At any rate it doesnt fit properly. Ultimately I need a new step and since the old one doesnt fit I cant take the old one to a metal fabricator to use as a template.

I also understand that the central coast company that used to sell the mast steps probably doesnt sell them anymore (though I will check tomorrow, it would be a quick and easy solution).

So I'm a bit stuck.

I like the idea of carbon fibre and kevlar. I am led to believe that carbon is about three times stronger than steel per volume (dont quote me though) and obviously enormously lighter. It should be fine with constant loads and would be able to work to spread the load. I can also do the job myself.

Does anyone have any advice?

Jeremy,

My mast girder is made of aluminium and is envied by all who see it.

Jeremy,
You can make your old mast step fit with epoxy and high strength filler if you choose to repair it.
If you want the correct profile for a new one, you can put bog on plastic film on the cabin top and plant the old mast step on top of it and screw it down while it sets.
The new one will not be perfect and will need a good load carrying filler (as above) to transfer the load properly anyway.
I was quoted about $600 for a stainless mast step a few years ago and chose to repair and re-galvanise the old one. I did the welding myself but with the sandblasting, galvanizing and 3 types of paint it still cost about $300.
Cheers,
Tom

Looks very nice Phil. I am jealous. You may need to clarify, what is the difference between a step and a girder? wouldn't the lump of metal under a top hats mast be both?

Good point Tom, I hadn't thought of sitting the old girder in bog on plastic to give the correct curve to use as a template. So simple, I think I will pursue this further. $600 as a ballpark figure is feasible. I was thinking if the cost was towards the $1000 mark I would look at other options.

Jeremy