Broken gooseneck, redesign needed

[sanibel sailor]

After I switched to midboom sheeting, my zealous crew bent the boom on my 1979 Bristol 35.5C. I replaced it with a stronger used boom, custom fabricated a toggle to attach it to the stock mast fitting, which is a vertical piece of aluminum that rides in the sailtrack, fixed in position by machine screws above and below. This arrangement seemed like the weakest link. The new boom came with a mast bracket that did not fit the mast profile.

Sure enough, did a gybe yesterday and the mast fitting tore out of the sailtrack. I have repaired it by moving it above the damaged area but I need a new attachment method. Mast was made by MetalMast Marine, oval shaped, section MM8655, but they’re now out of business. No matching parts in the RigRite catalog. I plan on calling RigRite Monday and seeing if they have anything that will work, but I am expecting to be disappointed.

Thinking I may need to design and fabricate a new attachment. Any words of wisdom? Seems this is a frequent failure point offshore and this could be a chance to make it robust.

[svHyLyte]

John--


Don't waste your time with RigRite. They won't be of any use. Instead, contact Guido at Garhaurer Marine. They have fabricated several stainless steel mast fittings for me at very reasonable cost. The work is excellent and the fit and electro-polished finish high quality. You can't do better.


FWIW...


PS: Add a "Boom Brake" to your kit to prevent damages in the event of an accidental gybe in future.

[sanibel sailor]

Thanks, I will put them on my list of options. It was an intentional controlled gybe at the mark on a boat with experienced crew. Just a design flaw, although it lasted almost 40 years.


Likely I will have one fabricated/welded locally out of billet aluminum parts which I can make and fit prior to being welded. I have a mistrust of both cast aluminum and stainless.

Here's the one that did not fit. Going to do similar design I expect.

[Boatguy30]

That gooseneck was used on boats like Shannon 28s. Surprised to see on a 35'

Having a welder fabricate something would probably be the best option. Needs to be approx 1.5" wide straps bent to bit mast to about mid cord. Then tangs welded to back to bit the block that goes into boom tangs.

Happy to consult further if needed via PM

[sanibel sailor]

I’ve been thinking of something along these lines.

[Djarraluda]

Just a note of caution if you machine one from alloy, check the material.
Domestic (?) grades of aluminium use alloys that corrode badly, ensure it is made from a marine grade. Obviously stainless steel should be 316L if you go that route
Roger

[01kiwijohn]

Had a similar situation, different fittings. I dropped the stick and made a backing strip of 1" x 5/8" aluminum to fir inside the mast. Drilled and tapped it to suit and it's as tight as the day I built it. Also, drill a couple of smaller holes so you can pop rivet it in place so that it won't drop out if you forget, and undo all the bolts, later. I could possibly send you a sketch if you're interested.

[sanibel sailor]

Originally Posted by 01kiwijohn

Had a similar situation, different fittings. I dropped the stick and made a backing strip of 1" x 5/8" aluminum to fir inside the mast. Drilled and tapped it to suit and it's as tight as the day I built it. Also, drill a couple of smaller holes so you can pop rivet it in place so that it won't drop out if you forget, and undo all the bolts, later. I could possibly send you a sketch if you're interested.

Interesting idea, hadn't planned on pulling the mast. Here in Florida, it is not done routinely so it is kind of a big ordeal.

[sanibel sailor]

Originally Posted by Djarraluda

Just a note of caution if you machine one from alloy, check the material.
Domestic (?) grades of aluminium use alloys that corrode badly, ensure it is made from a marine grade. Obviously stainless steel should be 316L if you go that route
Roger

Tentatively planning 6061 alloy, but I will check with the welder first. Also need to see it there will be warping or other issues with welding a thick horizontal piece (I'm thinking 3/4") to the 1/4" side straps.

I have a 1/4" long section from the butt of the mast that I cut off due to corrosion. That will be helpful to check fit of the pieces.

[sanibel sailor]

Originally Posted by svHyLyte

John--


Don't waste your time with RigRite. They won't be of any use.

Prophetic. Three weeks, no response. Same unhelpful bitchy lady on phone saying next week for several weeks.

[sanibel sailor]

After 4+ weeks, RigRite finally responded, $500 for a custom. Online raw material $50 with shipping. Fabrication $80 including drilling a 5/8 hole thru a chunk for the toggle. Happy!