Cutting the mast, loosing an inch

[kkearns]

On the topic of crazy things previous owners have done, the mast on my DSI was cut at a slight angle about a foot or so above the cuddy, and the previous owner fabricated an aluminum "sleeve" into which the top portion of the mast slides down to meet the bottom portion. The sleeve has drilled holes which align with drilled holes in the mast, allowing the insertion of bolts above and below the cut secured with wing nuts. You can imagine the difficulty stepping and lowering the mast with this arrangement. For example, I cannot do either of these tasks with the side stays attached. My partner and I must lift the mast vertically (and precariously) while trying to slide it into the sleeve.

Anyway, I want to cut the mast at proper 90 degree angle and install the hinged tabernacle available from D and R Marine. In doing so, I will likely lose about an inch (perhaps a bit more) of the mast height because I will be removing the slight angle on which the mast was previously cut. Sounds confusing, but take my word.

The question is, will this loss of an inch or so cause a problem? I'm thinking that the only real problem would be the length of the side stays and forestay. Both are on turnbuckles and I may be able to adjust them to accomodate for the lost inch (don't know for sure ... must wait till I get the boat out of the barn in the spring). Should I install a little "lift" at the mast step on the bottom beneath the cuddy to compensate for the lost inch? If so, any suggestions for how to do this? I'm thinking that a small wooden block screwed and epoxied to the stringer beneath the current mast step should do it. Lastly, for you guys with metalurgical engineering skills, will the integrity of the mast be compromised by having those holes drilled through it if I no longer need the through bolts? My guess is "no" but would appreciate your advice on this.

Thanks,
Kevin Kearns

[GreenLake]

Not a mettallurgist, but unless the holes are extreme, I don't think you'll have issues. (Extreme means size and pattern, i.e. rows of holes). Nobody can tell for sure unless you provide drawings or pictures.

Whatever pedestal you create, make sure it's strong for compression loads. Wood with vertical grain might split. Plywood that's well-saturated in epoxy might be the ticket.

I see no gain in screwing such a support - with a tabernacle the side or for and aft forces shouldn't be transmitted to the mast step any longer (one of the reason these masts perform less well than uncut masts.) If I'm right with that line of thinking, expoxying that block should be enough to hold it in place.

[dannyb9]

the dr tabernacle requires that about 1.5 inches be cut off the mast at the tabernacle location anyway. so i think youre set

[algonquin]

You should be good with the stock mast step and adjustable turnbuckles. As far as the holes in your mast go I don’t believe they will cause any loss in structural integrity. If you ever tried to tear an old style postage stamp on its perforations you would understand what I mean. They rarely tore along the holes. Brad

[kkearns]

Thanks, everyone, for your advice. I did not realize that the tabernacle required that type of cut to the length of the mast. Now that I think of it, the thickness of the tabernacle itself would likely make up for most (or at least some) of the lost length of the mast, right? I had not factored that into my thinking.

Anyway, these are the things we ponder on days when the leaves are falling and snow will soon be on the ground.

Kevin