Stainless screws, Aluminum mast

[Us4byrds]

I've taken the mast off and removed all attachments. In the process a couple of stainless screws have broken off and proved so far impossible to remove. My question is, what if I just smooth them out and leave the remainder in the mast? Will it corrode around the screw and eventually fall out and leave a hole? or will it just stay stuck in there forever and not be a problem?
I should add that I am planning coats of Ever Bright for the finish.

[a64pilot]

I don’t know what ever bright is, but if left here they will probably still be there after we are gone, besides what would you fill the hole with if they were removed?
I assume no fastener is needed there, just the hole filled?

[billknny]

Originally Posted by Us4byrds

I've taken the mast off and removed all attachments. In the process a couple of stainless screws have broken off and proved so far impossible to remove. My question is, what if I just smooth them out and leave the remainder in the mast? Will it corrode around the screw and eventually fall out and leave a hole? or will it just stay stuck in there forever and not be a problem?
I should add that I am planning coats of Ever Bright for the finish.

If you leave the stub of the fastener in the mast, and paint over it, I guarantee the finish around it will bubble up and fail.

[skipmac]

Originally Posted by billknny

If you leave the stub of the fastener in the mast, and paint over it, I guarantee the finish around it will bubble up and fail.

Yep. Had it happen on a boat I bought with a painted mast. Finish did exactly that around every SS screw and fitting on the mast. In places the bubbling spread several inches from the fittings.

[Us4byrds]

Correct. No fittings are needed there. Thank you a64pilot. billknny and skipmac what do you suggest I use to fill the holes if I ever get the studs out of them?
FYI Everbright is a clear coating to put over the aluminum to keep the shine.

[a64pilot]

Is there something wrong with the anodize now?
Almost said Alodine.

[a64pilot]

To get them out, I’d drill a hole through them, then heat the area as much as I was comfortable with and try a screw extractor, that may work, if it didn’t then I’d just drill them out.
Only thing that comes immediately to mind to fill them is a pop rivet, but boy would that be a big pop rivet.

[Emmalina]

Durolac when you re-assemble ! Yes you need to get the old studs out !

[S/V Alchemy]

Originally Posted by Emmalina

Durolac when you re-assemble ! Yes you need to get the old studs out !

Another vote for Duralac, although there are several similar products to keep different metals in contact from galling and corroding.

[Terra Nova]

Drill out the broken screws using a cobalt bit. Apply Tef-Gel to fasteners.

[jharding]

heat is your friend, use heat to expand the aluminum and loosen up the corrosion, I like using left handed drillbits, start with a small bit and keep going bigger until bit catches and backs out screw, drilling stainless you need to drill slowly with a lot of pressure, don't let bit spin fast it will work harden area and then is a real bitch to get through, also don't break off small bit, then you are really screwed.