Elongation and Cracks at Spreader Bars in Aluminum Mast

[Dennis Boyd]

Hello everyone,

The purpose of this email is to ask group’s opinion on some mast defects found on Jaywalker.   Lower spreader bars, are loose and working the mast cut outs.    Lower starboard side is mashing the aluminum as it works. Upper spreaders bars, are loose and beginning to propagate cracks.  There are cracks on both sides of the mast, and upper port side is largest.  It is about 3/8 of inch, but still hidden by the spreader itself.

See pictures.

My guess is that I will have the yard remove some paint and examine just how damaged extends in these areas.    I am just wondering if anyone else has seen this sort of elongation and cracks in an older rig?     If so what repairs were used. My hope that it is repairable.   But, if this a nonstarter, I would like to know sooner rather than later.  

Thanks again for your help.    

Dennis Boyd  Jaywalker #6

[WSC]

My two cents (not a professional rigger) as I had the CF mast on hull #1 professionally refurbished last season.  I had similar "cracking" at these fitting points for the spreaders, along with some other crazing and suspicious areas of concern.  After sanding the old paint off, they said there wasn't any areas of concern, and it was all cosmetic.  After final prep, four coats of primer and five coats alwgrip, the mast looks better than showroom.   I'm hauling soon so will be interested to inspect how the spreader areas look after one season.   As for the "looseness" in the spreader fittings and bars, my local rigger told me this is normal - you need a bit of wiggle room to get the spreader fittings in/out of mast, taking into account thermal expansion, etc.  So I'd chalk it up to normal wear and tear, and the importance of annual inspections.

Sean Conner - VIDA J42 #1

[Wayne Cassady]

I’ll add my two cents. Also not a rigger and would definitely get a couple of opinions from riggers. It’s easy to see how a leeward spreader could “hammer” at the fitting to the mast while sailing through some waves. Leeward shrouds would be loose and allow the movement. Small cracks at that location would not seem to be a concern.

Sent from my iPhone

On Sep 29, 2025, at 6:16 AM, 'WSC' via J/4X Owner's Group <j4x-owne...@googlegroups.com> wrote:

My two cents (not a professional rigger) as I had the CF mast on hull #1 professionally refurbished last season.  I had similar "cracking" at these fitting points for the spreaders, along with some other crazing and suspicious areas of concern.  After sanding the old paint off, they said there wasn't any areas of concern, and it was all cosmetic.  After final prep, four coats of primer and five coats alwgrip, the mast looks better than showroom.   I'm hauling soon so will be interested to inspect how the spreader areas look after one season.   As for the "looseness" in the spreader fittings and bars, my local rigger told me this is normal - you need a bit of wiggle room to get the spreader fittings in/out of mast, taking into account thermal expansion, etc.  So I'd chalk it up to normal wear and tear, and the importance of annual inspections.

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[Dennis Boyd]

Wayne,  Sean.   

Thanks,   I am still waiting for some feedback from a couple of guys (riggers).   

I will keep everyone posted on how this plays out.   I am really wondering if any other Aluminum mast guys had to address this yet?     Also fyi, these cracks and elongation were hidden, by the spreaders.  So I while I consider a man lift / aloft rigging inspection during survey/haul out,    That effort would have missed these issues.   So, in hindsight, I'm glad I don't spend those dollars. 

on a wild tangent, has anyone replaced rig yet?   

Dennis

S/V Jaywalker  

J42 #6

[Wayne Cassady]

I go up the stick twice a year to inspect and put on Awlcare polymer, 15-year old paint still nearly looks like new. I would have never been able to see what you exposed with the spreaders off.

Sent from my iPhone

On Sep 29, 2025, at 2:39 PM, Dennis Boyd <dennis....@gmail.com> wrote:

Wayne,  Sean.   

To view this discussion visit https://groups.google.com/d/msgid/j4x-owners-group/cc48a9e7-5a59-4cfb-8c8e-3dcafc761fe5n%40googlegroups.com.

[WSC]

RE: replacing the rig.  I did all new rod in '22 to the tune of $9K just for peace of mind.   My insurance company told me the CF mast was valued more than $2X everything else combined to replace.  Not sure that is reflected in the resale value - lol.   

Sean C