Mast step replacement successful!

Following Matt Miller's excellent guide, I was able to replace my broken mast step with a new one in about 45 minutes.

The tools and replacement parts (mast step with proper rivets);


First step, drill out the old one (remove head and punch out the remaining cylinder);

Basically use 1/4" drill bit and drill out the rivet heads, use punch or similar to knock the cylinder through.

Once I did that, it literally popped up above the bar like this;


Now I simply unscrewed the old mast head and screwed in the new one - use care as you need to make sure you are not too high into the mast base. These new ones the hole goes all the way through, and according to Matt you need to make sure it's a smidge below or you'll run into problems with your bearings wearing out etc. To get it seated, I tried the clamping trick, then went to the jack on the dolphin bar area, then in addition I had to rasp file the aft side and I used a rubber mallet and a ratchet extension to smack it down (not hitting the casting at all, just the bar in the middle bottom of the casting. Here I am with the jack in place, one of the clamps and putting in my first rivet;


The one thing I didn't realize about rivets is you push it up tight to the rivet and clamp the handles together, release and shove forward and clamp again, and then it usually snaps off at that point. I had to do it up to 4 times to get it to go on some of them. Finally done (don't mind the orange paint on it - that was from the clamps);


Once complete the key thing is to go back and tighten up the dolphin striker nuts on the the two ends of the boat under the corner castings. I should also mention, it's a good idea to loosen those prior to clamping things down as it makes it easier to do.

Not the best how-to in the world but really just gives a flavor for what is involved. See Matt's document here;

http://static.hobiecat.com/2010_archive ... eplace.pdf

Thanks Matt for creating that guide!!

-Lyle

I also have replaced several mast steps (and mast bases) over the years, but it took a lot longer than 45 minutes (probably due to saltwater corrosion).

After removing the old rivets on the old mast step, I could not just twist it off since it was fused to the dolphin striker post due to saltwater corrosion over 30 years. I had to cut the old mast step casting into 3 pieces in order to free it from the post.
To get the new mast step casting to line up with the top of the crossbar (old style without integrated track) and the dolphin striker post I had to do some filing in 3 places to get it to fit. The threaded hole for the post in the new mast step casting was about 1/4" aft of the top of the post (where it came up through the crossbar). I had to slightly enlarge the aft side of the upper striker post hole in the crossbar (as Matt recommended). I also had to file down some of the aft edge of the crossbar (where the casting "hooks" over it) and slightly filed down the inside of the lip of the casting where it "hooks" over the the crossbar to get the mast step to fit flush with the crossbar prior to riveting.

Loosening the nuts on the dolphin striker bar was also interesting. One of the nuts (and a piece of the bar) broke off, fortunately there was enough thread left on the bar that I could put a new nut on it. The other end's nut came off fine.

After filing and using clamps, the new casting now fit nicely on the crossbar. I couldn't figure out how to drill exactly through the new casting into the old rivet holes of the crossbar so I drilled fresh holes and riveted instead.

A few years later, I helped a friend replace a mast step on an 80's H16 and ran into the same problem with the mast step corroded to the dolphin striker. Having dealt with this before it was a lot easier this time using a sawzall and some wedges to cut/break the old mast step off.

_________________
Tim
84 H16
82 H16
87 H14T
Tortola Sails: 115222
Blue Prism Sails: 88863
Clearwater, FL

Wow yes that was way more involved! Mine, I believe, has been landlocked in the middle of the US - so never any saltwater. Took just a decent twist to start it (by hand) and it unscrewed right off. I cleaned up the threads with a wire brush but really it looked fine and probably didn't need that done. I also had marked the old rivet hole locations and then drilled new ones away from those spots - just as you did.

As it is though, the front rivets that I tapped out of the holes, have fallen into the tramp chase area. As luck would have it, I need to replace that as well so I will get those out at that time.

Amazing how much more confident you get in repairing things once you've done them once before. I figured I'd be in for a few hour deal, IF I could even get it done. Not too bad... *knock on wood*

-Lyle

Looks really nice. When will you replace the mast base to match?

_________________
'00 H16 #104691
'78 H16 #32692 ex-rental [gone]
Old Holsclaw trailer
My Hobie 16 pages

Anton, whenever you're ready to come out and help me do it!!

I can see where when you start replacing stuff, you think, oh, I should fix/replace this too.... next thing you know you're 10g in to a 30 year old boat and could have bought a new one...

I have to hold myself back - I'm also needing a tramp and I have my side rails to redo. My dilemma now is we are at the end of the sailing season (or close too it), and I'm thinking of just getting those parts and then replacing them in the spring since the boat will sit outside and that would just be a winter of wear for no reason.

I hope to get it together enough here to at least get out once this year. Watching weather, and hoping my nutty schedule allows it!