Mast Step trouble

I'm replacing my mast step and have read how to but what worry's me is the fact that I think this will be the third mast step on the crossbeam and the holes that are there are wallered out from previous drilling. I was thinking welding them but the heat treatment is an issue.

So now I'm down to either just putting six rivets (3 in the front and 3 in the rear) in it and hoping that the outer rivets hold
or buying a new crossbeam which I can't afford right now.

What do you think guys?

btw my mast base has crap for threads, are they all that way? or do i need to tap it?

First thought is to go up to the next size larger rivets (1/4" dia.) and drill out the holes in the mast step to accept them.

Second thought would be to use the standard 3/16" dia rivets with washers to back up the crossbar holes inside the crossbar. I don't know if it can or has been done, but the thought would be to pull the mast step and dolphin striker post off of the crossbar. Then insert washers behind the existing rivet holes (insert them through the dolphin striker post holes). Place a small dab of silicone on the washer. Then, using an approximately 3/16" dia line, thread the line into the crossbar through the rivet hole, out the dolphin striker hole, and through the washer- tie a stopper knot in the line. Then pull the line tight so the washer is pulled flush to the inside of the rivet hole and hold the line there until the silicone cures. Once cured, pull the line out and install the mast step using the existing holes.

Last option, search the classifieds for a used crossbar in decent condition. You can probably find what you need for around $100 to $150.

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Probably going to just go up in rivet size. Also do you think I should use stainless rivets? Reason I'm asking is because stainless steel would probably waller out the aluminum...

The second idea is good but I'm not so sure i'll be able to drill and hit the existing holes dead on & through the washer. Thanks for the fast response!

If anyone has a crossbar for sale, I live in east TN and will drive a good ways to get one.

Absolutely use stainless or monel. Aluminum rivets have very little shear strength. They are good for batten pockets and stuff but nothing with any real stress.

OK, thanks for the reply!