Wooden mast repair and paint recommendations

[Arcos]

I have a box construction wooden mast that has been neglected for a few years.
The paint has flaked off and the wood is showing some checks or splits in some parts.
This picture shows the worst parts https://photos.app.goo.gl/31GET5nYLQN5gXf6A
My plan is to coat it with west system epoxy to saturate the cracks and then paint it over. Unless I get some recommendations on a better procedure.
Also what paint would you recommend?
Thank you for your input.

[Manateeman]

I can’t seem to download the photos.
When I started boatbuilding, a lot of boats had wooden masts. Some were just solid trees. The box construction types were often varnished. If there was a bad spot, you could easily see it as it as often discolored or black.
Common areas. Which caused failures were above any interior blocks and the heel. Masts took a lot of work to maintain. As a rigger I would never climb a spar I had not looked at on sawhorses.
Paint...rather than varnish...makes it a lot more difficult to inspect.
I’ve taken a number of wooden spars down to bare wood to inspect and varnish.
I know you don’t want to hear this but I don’t want to see you invest a lot of time and money in trying to correct something ...epoxy is not a magic wand...and in this case, even with expert help, it might not salvage the spar.
My recommendation is to find an aluminum spar.
Happy trails to you.
Captain Mark and his crew of old but wise manatees

[Wind River]

In your picture it appears as if your glue joints are coming apart. Saturating with West Epoxy is not going to fix this. Likely there is rot inside at this point.
I have Wood masts and my mizzen looked better than yours does. I had a couple of cracks and with a bit of poking it was obvious there was a bigger problem lurking inside.
I have not repaired it yet but wish I had at least bought the lumber for it. I can't imagine what it will cost with prices through the roof right now.

[Jim Cate]

I can't imagine what it will cost with prices through the roof right now.
_

Bauxite Pine is much cheaper than traditional spar timbers... and is rot free, easy to maintain and quite strong.

Jim

[Wind River]

Originally Posted by Jim Cate

Bauxite Pine is much cheaper than traditional spar timbers... and is rot free, easy to maintain and quite strong.

Jim

Thanks for the tip.

It appears mine are Spruce.
You wouldn't know if it is similar in color? I need to replace one side of my mizzen and will likely coat it with Awlwood MA. I would hope it will not look too much like a patch.

[Arcos]

Thanks to all that replied so far.
I will haul out and take the mast down in a few weeks and check for rot inside.
What is the best way to inspect the inside of the mast?

[Fore and Aft]

Arcos, there is really no way to check rot inside the mast. I was on a Lyle Hess yacht last week with a timber mast. The owner had epoxied it then coated it with lots of varnish years ago. But now the epoxy and varnish are coming of in large blisters.
As for finding some timber, I have successfully found a good range of Oregon in house demolition yards. Tight grain and so dry.
The old Dugong lover is right in saying a used aluminium spar could be the way to go.
Cheers

[ayates]

I had a boat builder repair my wooden mast which was starting to delaminate. Here is his write-up on the process:

Wayfarer hollow wooden mast restoration


Allan.

[bailsout]

I put West System 207 epoxy on my spruce masts. Big mistake. I now use Smiths penetrating epoxy-like a sealer with great penetrating ability. Then varnish. I’m still chasing West System failures around the boat. Your “rot” May be only cosmetic. Investigate further after a good sanding.

[Rough Magic]

I have to agree the photo shows the glue lines are failing. After you un-step, take off all the hardware, and see if you can disassemble (steam?) the joints and inspect the wood, especially around the hardware fasteners (holes can be repaired, but only if the surrounding wood is sound). If you see any rot or mold, I'd make a new mast, or buy an aluminum one. If clean and sound, you can re-glue and then varnish/paint.

[peter loveridge]

I've made 5 wooden masts from scratch. I had to make a machine to do the scarf joints as I didn't think I could make them well enough by hand. The last two I managed to get Douglas fir from BC in 36 foot lengths so I could do it in two halves and just hollowed out the middle. Coated it with 3 coats of epoxy. The thin stuff is better, but not available in Nova Scotia. Then 5 coats of Cetol. Its been good for 5 years but may need to be done again soon. Douglas fir is a bit heavier than spruce but much more durable . If the glue lines failing you MIGHT be able to very carefully get it apart, clean up the stuff and reglue it. I considered an aluminum mast, but my children said it would destroy the soul of the boat, It was a bit of a challenge to get 36 foot lengths of wood from one side of the country to the other, but we managed it. Came out about the same price as a new aluminum one

[bailsout]

I liked that you listened to your kids. Wooden masts are a lot of soul. And as you know, a lot of work.