Mast Refit (part 3)

[patentnick]

With the forestay fittings finished and the parcel containing the mast steps finally here, it was time to start drilling the 60 holes required for the installation. I chose to install aluminium folding steps by Mast Walker, since they combined light weight, strength and aesthetics. The top two steps are of a fixed, closed-loop design, made out of stainless steel, and provide a very secure foothold when working at the masthead. On average, a distance of 40-45cm is recommended between each step. Of course, this will vary according to the existing mast fittings, so in some cases you may have to be a little flexible. As the crosstrees provide a foothold by themselves, I measured the distance from the crosstrees to the main halyard winch (my first “step”) and again from the crosstrees to about 140cm from the masthead. The latter would give me a comfortable position to work on the various masthead fittings, plus VHF aerial, wind indicators, anchor light, etc. The mast steps can either be riveted or screwed to the mast. I chose to do the latter, which required first drilling with a 5mm bit, then tapping with a tap for 6mm machine screws. The holes on the mast—as well as the ones on the aluminium steps—were coated with Duralac, an anti-corrosion paste which also acts as a medium-strength thread-locker.

All in all, I’m really happy with the results. In fact, I got to try out the mast steps on the day the mast was refitted to the boat; I climbed up to install the wind indicator for my wireless instrument, since the crane operator wanted it removed before lifting the mast.

Nicholas

[MarkRyan1981]

Great effort Nicholas, thanks for posting it.

[prjacobs]

Awesome job, Nic. Thanks for the detailed info and great pictures.
I have a set of aluminum mast steps right at the top, and use a MasteMate to get up there, which is a satisfactory arrangement for the type of sailing I do. The aluminum steps, over time, become a little hard to unfold, but nothing that a gentle tap with a plastic mallet won't cure.
When I rebuilt No.1085 my galvanized beams were in good shape too, but because the new bulkheads were slightly thicker 1/4" had to be shaved off the ends and re-welded.
Anyway, you should have no rig concerns for a long time to come!

[patentnick]

Thanks for your kind comments guys.

I used to climb the mast with a 50m length of rope running through a 4:1 block-and-tackle, plus a climber's harness and ascenders/descenders. It was safe and, once aloft, quite comfortable but took some time to set up. Now, using the same harness and the ascenders/descenders gripping the spare genoa halyard, I can climb up really quickly. I liked the Mast Mate but due to the fact that I have a special track for roller-bearing mainsail cars, it wasn't an option.

Nicholas

[Newanusca]

Very interesting Nicolas. I see that you are very precise and you like to do things very well. What has surprised me is the state of the components after so many years. The philosophy of those years was to do things well for a long time.