Corner casting replacement

Hi,

I have a 1984 HC16. When I bought it two years ago, as a complete novice, I noticed a small horizontal crack on the left-rear corner casting. I was assured at the time that it was of no consequence.

Since then, the crack has gradually widened and a crack has also opened up on the right-rear corner casting and so I decided to purchase two new corner castings.

Unfortunately, I do not have the knowledge required to replace the castings. I am pretty good at fixing things and using most tools but I would like to get some help on the following:

1) I imagine I would need to de-step the mast. Is there an easy and safe way to do this?
2) I also imagine the corner castings will be a real pain to remove, not only from the pilons but also from the rear crossbar. Given that both castings are damaged is cutting an option? What advice can anyone give me on removing these old and damaged castings? Obviously I don't want to accidentally remove the pylons.
3) When it comes to setting the new crossbars are the rivets essential? Perhaps I could glue them instead? If so what sort of glue? I am not sure if I can obtain the rivets required 3/16 x 1/2 PH-SS here in Italy.

As mentioned the HC is quite old now and all things going well I would like to replace the old girl in a few year's time with a newer one but I would like to do a good job replacing the castings.

Lastly, as a side question, I wanted to know if the sort of crack I see on the corner castings are a symptom of a more serious problem?

Thanks for any help you can give. I have got a lot of good information from this forum and in most cases it is the only place to come for advice.

I needed a corner casting replaced on my boat a couple years ago.I know it is do able but I was glad to have my Hobie dealer do it.Not to insult you, but judging by your questions I would get an experienced handy hobie guy to help.

I agree with Madge - the job isn't that difficult, but if you've never put the mast up or down, I'm not sure you should be trying this yourself.

A boat that old should come part very easily. The rear crossbar is the easiest. There is no need to cut the castings off. Shear the old rivet's heads off with a cold chisel, then knock the rivet tails into the crossbar with a punch. The castings should slide right off the crossbar.

If you want to do it yourself, you will need a heavy-duty rivet tool, a drill, a rubber mallet and the aforementioned cold chisel and punch.

Barring any complications, it should take only an hour if you hustle and don't have a beer in your hand.

Thanks for the tips. In a perfect world I would have someone around that could help me but barring other club members whom I am sure will help me de-step the mast, it looks as if I am on my own.

Thanks again.