Total mast re-do

Heya, looking for some help from some more experienced folks here. Here's the situation:

My sailing partner and I have recently combined boats (creating the best boat of the two, "Franken16", and a leftover that will be sold, still a solid boat but not as raceworthy). We have one CompTip mast but it's a mess.

It has some serious leaks, we are not sure that the CompTip was installed very well, and we need to replace the mast tang as well (it has the original 1-hole; we are going to steal the more modern one from the aluminum mast).

So, questions for those who have disassembled and reassembled masts before:

(1) How easy will it be to get the CompTip off? I've heard that heating with a torch will soften the glue and expand the aluminum and pop the tip off, but how much of a struggle will it be? I don't want to damage the mast.

(2) Where is the mast sealed? Is there a foam plug at the top and bottom, or only at the top? The mast was insta-foamed at the Comptip, will we have to replace the plug or will we be able to dig some of the insta-foam out and re-do it?

(3) From the CompTip installation instructions, it says to drill for the mast tang - do the rivets seat through both the CompTip and the aluminum?

(4) What's the best glue to put the tip on with?

(5) Any other tips for water-tightness or tips in general (besides "don't do it", we already know that one! )

Thanks for any and all help!

_________________
Tim
Unofficial Fleet 72 Communications Officer and Div 4 Webmaster
http://www.hobiefleet72.org
http://www.div4.hobieclass.com/

First, it is difficult to remove the old comptip without damaging it even with heating. I tied one end to a tree and the other to my car and backed up, heated the joint, banged it around alot and it slowly slid apart.

Second, (should be first, but oh well) There are a couple of comptips out there. The really old are shorter and do not get riveted by the mast tang, the newer are a little longer and the tang rivets hold it in place.

My advice is to buy a new comptip and have the dealer install it in the solid mast.

If you are to do it yourself, measure twice, cut once.

I removed a comptip from a Hobie 18 mast last week.

First of all, why do you think the comptip wasn't installed properly?

As far as replacing the mast tang goes, don't be too cheap here. Just buy a new one, as they are rather inexpensive. I've had one break before, and it was quite a rush having a mast chase you down while you're on the trap!

If the comptip is not loose in the mast, and is aligned, leave it alone and seal up the mast with 3m 4200 (which they make in black to match your mast color!).
If you decide to remove it, use a little heat, a rubber mallet, and a winch or "come-along," and you shouldn't have any trouble.
For putting it back on, clean off any old glue/resin/etc with sandpaper, and I'd leave a little bit of a rough surface. 250 grit paper should do it. Clean the inside of the mast and the comptip insert with acetone next. To get a good seat inside of the mast, use bondo or the like, and paint it onto the comptip insert and a ring of it inside the mast as well. You'll be able to wipe/sand off any excess after installation. **Do not use any sort of fiberglass or resin or 5200, as you will never be able to remove it again if need be**. Slide the comptip in the mast, and use a mallet to tap the top of it to make sure it is seated well. Go ahead and re-rivet your mast tang as well using stainless rivets, and also be sure to put some sealant between the mast and the tang. The rivets go into the comptip as well. Hobie makes some rivet sleaves that can be inserted, but they aren't necessary if you seal the rivets up with sealant/4200. Once the bondo has kicked (about 8-10 minutes), clean any excess off the mast with sandpaper/acetone, and seal the connection point with sealant/4200 as well as any other leaks on the mast around fittings/rivets/etc. You should be ready to rock!

_________________
Trey Brown
www.velocitysailing.com
2006 N20 1017
1998 H16 102698
www.sunjammers.com ftw!