Ericson 33 – 1982 Keel-stepped mast
Please help me with advice on what I’m going to find on this project – and how to fix it!
Background:
Having read in the past about mast steps sinking, I have had a discipline for years of making a fairly precise measurement each year of the height of the cast aluminum mast step with respect to the cabin sole.
Last year, for the first time, the mast step had sunk 1-2 mm ( about 1/16”).
Upon examination, we noticed that the back to corners of the mast step had snapped off. Then we noticed cracks in the fiberglass underneath the mast step. The aft edge of the wide fiberglass rib upon which the step sits was cracking and sinking.
(This photo shows the wide transverse rib upon which the step sits – it was taken when we were putting in the new floor a few years ago - the step was not yet sinking and we ignored the cracks visible in the wide rib (probably a mistake!))
This week:
The mast is out of the boat. We removed the four lag bolts and the cast aluminum mast step came off easily – in two pieces – the aft 1” of the step (not just the corners) had been broken off. We immediately noticed what may be the root cause of this whole problem. Underneath the mast step was a smaller rectangle of four open screw holes. I’m thinking that this is not the original mast step (? not the original mast?) and that someone just carelessly put the current step over the old holes without sealing them. So for the last twenty years that we have owned the boat mast water has been leaking down into the rib structure.
(Note: The Rig-Rite catalog photos and measurements indicate that we have a Schaefer mast)
Today:
I had to start somewhere, so today I cut a rectangle of fiberglass out of the step area, cutting exactly between the old, open, screw holes.
I’m not too surprised. There is wood under there, and it is completely soaked. There is a gap – the wood is separated from the underside of the fiberglass, about 1/8” below the bottom of the thick glass. The wood appears to be split, with the aft portion a greater distance below the glass.
Overall question:
How do I fix this so that the mast step and mast are solid and secure? ( On the aluminum step itself, I know a good welder who will weld it back together this week)
Questions on the way…
How far does this wood go? How far port/starboard within the wide rib? How deep into the keep stub area?
Can I get the wood out and replace it with something better?
How structural is this port/starboard “wide rib” and how do I make the repair without compromising the structure?
Thank you for any advice and guidance! I know there were only 28 E33’s built, but I am hoping some other models may have a similar keel-stepped structure and other owners may have valuable advice!
Please help me with advice on what I’m going to find on this project – and how to fix it!
Background:
Having read in the past about mast steps sinking, I have had a discipline for years of making a fairly precise measurement each year of the height of the cast aluminum mast step with respect to the cabin sole.
Last year, for the first time, the mast step had sunk 1-2 mm ( about 1/16”).
Upon examination, we noticed that the back to corners of the mast step had snapped off. Then we noticed cracks in the fiberglass underneath the mast step. The aft edge of the wide fiberglass rib upon which the step sits was cracking and sinking.
(This photo shows the wide transverse rib upon which the step sits – it was taken when we were putting in the new floor a few years ago - the step was not yet sinking and we ignored the cracks visible in the wide rib (probably a mistake!))
This week:
The mast is out of the boat. We removed the four lag bolts and the cast aluminum mast step came off easily – in two pieces – the aft 1” of the step (not just the corners) had been broken off. We immediately noticed what may be the root cause of this whole problem. Underneath the mast step was a smaller rectangle of four open screw holes. I’m thinking that this is not the original mast step (? not the original mast?) and that someone just carelessly put the current step over the old holes without sealing them. So for the last twenty years that we have owned the boat mast water has been leaking down into the rib structure.
(Note: The Rig-Rite catalog photos and measurements indicate that we have a Schaefer mast)
Today:
I had to start somewhere, so today I cut a rectangle of fiberglass out of the step area, cutting exactly between the old, open, screw holes.
I’m not too surprised. There is wood under there, and it is completely soaked. There is a gap – the wood is separated from the underside of the fiberglass, about 1/8” below the bottom of the thick glass. The wood appears to be split, with the aft portion a greater distance below the glass.
Overall question:
How do I fix this so that the mast step and mast are solid and secure? ( On the aluminum step itself, I know a good welder who will weld it back together this week)
Questions on the way…
How far does this wood go? How far port/starboard within the wide rib? How deep into the keep stub area?
Can I get the wood out and replace it with something better?
How structural is this port/starboard “wide rib” and how do I make the repair without compromising the structure?
Thank you for any advice and guidance! I know there were only 28 E33’s built, but I am hoping some other models may have a similar keel-stepped structure and other owners may have valuable advice!