Step 1 went well. I agree with Russ that somebody may have engineered the mast step, but they seemed to encourage creativity as well. In my case I think they were building the mast step right before lunch or before quitting time. On the downside pict #3 show that there is not much inside the mast step. An extra 3-4 lbs of material here probably would have been worth the weight. On the upside, only the top deck is rotton. The vertical plywood and the rest of the mast step is completely dry. The drain must work. Considering this boat is 26 years old, I am very impressed!
So the fix will be:
1. remove balance of rotton deck with recip saw.
2. build a box (similar to Russ's drawing) in three pieces:
two outside pieces to tuck under the remaining glass, plus
one center piece to put in place once the two outer pieces are in place.
3. inject resin between the new box and the existing glass to fill space and create bond.
(Any suggestions here would be appreciated!)I will use Purple Heart to minimize rot. I will then build up and glass to exising fiberglass. I may add another 1" to the front of mast step, as my boast points better with the mast racked back.
Images below are:
1. Mast step still intact with mast resting on temporary support 18" above mast step. lSupport also served as collar to keep mast vertical during lift. Used spinnaker pole and a saw horse on deck to easily lift mast.
- Mast Step Still Intact
2. Inside mast step with top turned upside-down and placed in front.
- Inside Mast Step
3. Inside mast step with rotton deck removed.
- Inside Mast Step with rotton deck removed.