Mast Joint Repair

[Mark Kochendorfer]

I started a new thread now that my mast is apart.  The wear and damage is extensive.  Oddly enough it had one new style bolt (lower) and one original bolt.  Both are ovaled now.  The diamond pads reamed out the inner sleeve holes large enough to stick a pinky in them.  No heli-coil repair for them!  Some of the track screw holes are reamed out too.

I am going up to a 13/16" collar on the thru bolts and fabricating backing plates for the diamond pads.  I might put in a backing strip for the track screws also.  I ordered stainless collars for the diamond pad screws so they bear on the inner and outer sleeves.  I will bore them out to fit the collars (1/2").

I am considering a shim between the sections or pumping the joint full of g-flex epoxy.  I have no experience with either repair so if anyone has details please share that.  I have seen the threads which do not have details.

I am thinking that the epoxy repair might be easier than sizing a shim and forcing the sections together.  My idea on the epoxy is to use a 1/4 inch grease fitting in one of the track screw holes (yes a few of those were tapped out to 1/4") and a grease gun to pump. I will have to plug the back of that hole with a dab of epoxy to seal it.  I plan on putting all the other bolts and screw in place first.  I thought maybe I could seal the top (inner joint) with some epoxy putty put in place before I draw the sections together.    I think there is ample space in the joint for epoxy--I would guess .050 gap on average.

If anyone has experience with this please pass along pointers.

I am including a link to pictures if anyone wants to see how bad a mast joint can get and still not fall down. 

Mark

Peregrine 30U

[C]

Hi Mark,

 I have no direct experience, but there is a Hinterhoeller bulletin on the INA site under spars and rigging in which they suggest West system.  No details,  But years ago (at least 12-14) someone bought and shipped a 30 to Denmark, i believe. I forgot his name, but he epoxied his mast.  His experience over the long interval might be helpful. Maybe one of the longer term members remember him.  He published in the bulletin, and had some ideas concerning balanced rudders which generated a lot of discussion at the time.
Carl Linkinhoker
NS26C #146

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Date: Mon, 27 Apr 2015 15:57:06 -0700
From: mar...@gmail.com
To: INA-Nonsuch-Di...@googlegroups.com
Subject: Mast Joint Repair

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[R D Young]

I believe the gentleman you refer to was named, Klaus Naerra. He was a prolific poster to the owners list and spoke quite authoritatively about the mast joint and other engineering related Nonsuch matters. He sold his boat long ago but his posts and Update articles should be available in the archives for anyone who cares to look for them.

David Young

Bay Cat, 30U #402
Traverse City / Suttons Bay, MI

[mark fagelman, MD]

I think you need to get this inspected by a rigger who has lots of Nonsuch experience.

I have been on a Nonsuch at the time of of a mast failure at the joint, with the top coming down and just missing the cockpit.

That is no fun

mark fagelman

[Jeff Orlando]

My mast was repaired with epoxy about 5 years ago.  I've had no problems since.  The work was done by Schooner Creek Boatworks in Portland OR. (503) 735-0569. 

I originally planned to have the joint rebuilt with nuts and bolts.    Steve Rander who owns the yard suggested epoxy as a more permanent solution.  Maybe you can give him a call and get some guidance. 

The people at West Systems are very helpful too and worth calling.  ~20 years ago, I had a leaking 200gal aluminum diesel fuel tank. Removing the tank would have required gutting a large area of interior.  The West System engineer guided me through an epoxy repair of the tank by patching from inside.  Never had another problem with the tank for 10 years at least that I owned the boat.

Jeff

30-438 SummerPlace

Olympia

[alp...@sympatico.ca]

Hi Mark, when I did the mast joint repair I also noted that there was quite a bit of extra space between the two sections due to years of wear. To take up this slack we wrapped the lower section with one layer of sheet aluminum. We then crimped the upper edge of the aluminum over slightly so that it would not slip as the sections came back together. Before winching the sections back together we slathered both sections with generous amounts of dishwashing liquid soap. I had a friend stand at the very top of the mast and he twisted the top so that everything would be aligned as the sections came together.

We opted not to epoxy because that's a one way street. That's just a matter of personal choice though. I can't imagine wanting to pull the sections apart in the future but you never know.

Good Luck......Ron

Ron & Diane Schryver

"Alpha Waves" '87 NS30U #393

Midland ON

Awesome Georgian Bay

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Date: Mon, 27 Apr 2015 15:57:06 -0700
From: mar...@gmail.com
To: INA-Nonsuch-Di...@googlegroups.com
Subject: Mast Joint Repair

[Ernie Abugov N22 #56 "Moustaches" EYC-Toronto]

Wow .   that is an interesting group of photos.

 

You must be getting awfully tiring of hearing this but ...  what about a call to Mike Quill ?  Mike also works very closely with the folks at Klacko Spars - both reasonably close to Toronto. They are the best. Are you in or near Toronto ?

 

I really bet that Mike and/or Klacko can get that mast shipshape and trustworthy for "not a fortune".

 

Good luck.

 

Ernie A. in (Sunny, thank heaven) Toronto

[Mark K]

Yes I spoke with Mike--he has been very helpful.  I am in Duluth, MN, 900 miles away--probably there are rigging experts here, but I don't think anyone who has done this repair on a Nonsuch mast.  I thought I would take this on as a DIY project in any event.

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Date: Tue, 28 Apr 2015 11:28:25 -0700
From: eight...@gmail.com
To: INA-Nonsuch-Di...@googlegroups.com
Subject: Re: Mast Joint Repair

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