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Old 20-12-2024, 07:39   #16
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Re: Corrosion in unstayed mast step - how bad?

Looks like the galvanic activity is primarily from the copper strap attached to it. Copper and aluminum do not play well. It also looks like there is a copper coin sitting on the base. Not much galvanic activity elsewhere.
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Old 20-12-2024, 07:39   #17
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Re: Corrosion in unstayed mast step - how bad?

I owned a 35 and it would not sail to windward. I would not own one again.
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Old 20-12-2024, 10:00   #18
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Re: Corrosion in unstayed mast step - how bad?

Figure out the step replacement cost & reduce final offer by same ( hopefully your original was subject to inspection & sea trial)
- and while I agree carbon fiber on aluminum in a wet environment isn’t great, 1) fabbing a replacement in aluminum will likely be the most cost effective option shy of doing a proper engineering redesign (this is an unstated mast….very high loadings) 2) it’s a few decades old, so replacement in kind will likely out live boat…
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Old 20-12-2024, 11:13   #19
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Re: Corrosion in unstayed mast step - how bad?

Hi,

I have a Freedom 40 cat ketch. My understanding is that those collars are primarily to hold in place a dense plastic wedge that goes all round the carbon mast. If you sleuth around the Internet you will find some hits which will help your risk assessment.
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Old 20-12-2024, 11:55   #20
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Re: Corrosion in unstayed mast step - how bad?

Before you get too carried away with the need to replace your mast step, put a little carbide ball, or other grinding or sanding bit, into your cordless drill, and polish through the surface corrosion, just far enough to see if the aluminum is still shiny underneath.

Aluminum that has been compromised looks dull on the inside. I have heard it described as 'cottage cheese'



Polish up the mast step in several places, or put a nice shine and wax on the whole thing with little buffer wheels on a dremel tool. If it takes a nice shine, be happy.


If the aluminum will take a shine, clean the whole thing with white vinegar, rinse with baking soda in water, hose the whole thing down with fresh water, and go sailing.


If it stays dull under the surface, go to plan B: Make an overbuilt mast step out of carbon fiber, or even glass cloth in epoxy resin. You can build up a whole inch of glass for the step, and eliminate the conductivity of carbon. No need for a lightweight structure in this application.
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Old 20-12-2024, 19:18   #21
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Re: Corrosion in unstayed mast step - how bad?

Remove the collars and use them as a plug to to get a cast made in bronze.
Pretty simple.
Or get a custom made collar made of 316L SS...Pretty simple as well.
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Old 24-12-2024, 13:06   #22
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Re: Corrosion in unstayed mast step - how bad?

As barnakiel said, glass reinforced epoxy eliminates the corrosion issue. And the part can be molded around the parts with appropriate release material in between. No machining necessary.
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