Masthead repairs

  • October 23, 2015 5:25 PM
    Message # 3597808
    Deleted user

    just about to tackle a masthead repair on our Westsail 42 ketch (tall rig)

    The masthead has 3 sets of halyard sheaves, which are secured by a pin that seems to be held in place by a little diamond shaped screw plate on the port side. One of the 2 screw heads holding the aft plate has sheared off (probably just old don't think the mast has been serviced since 1974)

    This has allowed the pin to shift a little and while it hasn't dropped right out, it has bent the plate outwards about 5mm and the sheaves are jamming.

    We can't lift the mast where we are so I am going to try to repair aloft (luckily we have good mast steps.) I am hoping that I can get the plate off, knock the pin back into place and then retap the screw holes (maybe needed as guess I will need to drill out the broken screw) to replace with good screws. Know this will be tricky as have to keep the halyard up as a safety line but take the weight off while a work.

    So does this sound like a reasonable (if ambitious) plan and any tips, experience of previous repairs, drawings etc?

    All help gratefully received,

    Jane

    SV Chantey

  • October 24, 2015 12:00 PM
    Reply # 3598616 on 3597808
    Anonymous member (Administrator)

    Jane: 

    Sounds like an adventure and some risk with this project... I assume that there isn't a mast service hoist in the area?  (ie a crane with a chair to work from) 

    I've not done a lot of work up the mast but here is what I do when up the mast: 

    I find that both mast steps/ladder and a bosun chair work pretty good.  The steps/ladder let you climb up and the bosun chair gives pretty good access around the mast/work area.  I'll assume that the mast steps are all safe - not corroded - like mine were...  

    I also have someone below tending the safety line and I don't do any work while this person is below me - in case I drop tools etc. 

    I do secure the heavier tools with small cords and use spare halyards as hoist for the items forgotten below:) .. 

    Thinking about all the things that could go wrong... If you can avoid removing the broken screw - maybe just add another fastener in a slightly different location and leave the broken piece in place?  When I had to help my students remove broken studs in their car engines - I found that left handed drills work great. Many times while drilling out the stud the drill would catch and just back out the stud.

    On the ground removing a broken SS stud that has corroded to the aluminum is a challenge - doing it while up the mast is harder still. 

    Drilling SS is always slow going - maybe experiment on the ground? 

    Finally when you are up the mast - try to take a snap shot of the issues -- and of your boat:)  If you email me the picture I can post for you. 

    Hope this helps.. my W32 mast head is probably different from yours... 

    Jay Bietz

    Last modified: October 24, 2015 12:20 PM | Anonymous member (Administrator)
  • October 24, 2015 9:31 PM
    Reply # 3598953 on 3597808
    Deleted user

    Jane:

    I second what Jay was saying, and if your mast head is like the 32 then there are 6 sheaves  in the mast head 3 fwd and 3 aft with 2 aluminum plates, one on each side of the center sheaves, keeping the port line running on the port side ctr in the ctr and yes the starboard to the other side.

    Some additional thoughts:  how long ago did you service these (remove check, clean and regrease) ?  I have done this twice in 17 years = not the best, and should have been every 5 but I am lazy (I inspect once or twice a year while in the water). I do hate to do this work,  But both times I have had the mast off the boat. If YOU (not some one else)  has inspected and regreased these in the last 4 years ? Maybe just pushing the pin back could work?? but if not (which sounds like the case) I would take the mast down and do all the service on the ground. But if you are on an island 500+ miles from a yard I would bring a rag up and feed it through under the (sheaves, and tie it off so that things can not fall down into in the mast. And also rig a bucket to bring tools / parts up and down.)

    Climbing the mast is indeed not that much fun when you know everything should be right, Not sure I would do that, knowing something may be wrong, but with that note, as long as you have a safety you may not fall? as the line is captured in the mast head, but you may need the fire dept if it fails as the line would have to run over edges inside the mast head which would not work well if you try to come down.  

    SO I would never do what you are asking, unless there was not the option to take the mast down i.e. there was not a yard for 100's of miles which I could motor to (fixed mast) mine will tabernacle and I would take it down to do the above. Working at the top of the mast is not fun for me at all. While on the ground (sawhorse) I had the above parts fall to the ground 3 times when I tried to reassemble them, which required cleaning regreasing and trying again, so if you drop stuff down the mast UGH!!!!!!!!!!!!!! this will not work!

    My sheaves were aluminum with bronze bushing running on a ss tube (pin) last service I flipped them as there was some (Not allot but some) ware on the ss tube (pin).  If the cover came off,  I would guess you have issue with the sheave griping the shaft which would turn the shaft which would try to jack the little plate off the mast; but that is only if your setup is like that on the w32

    Hope this helps

    Norm 

    p.s. I reread your post, and if true, last service 1974. you may want to order new sheaves, plates [not cover plates but the ones between the sheaves] and pins from Bud before going up as it is likely the bronze bushings are failing or they have eaten into the ss tube (pin) and made it not round.

    Last modified: October 27, 2015 6:16 PM | Deleted user
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