New Mast Step

Old Mast

The original LF38 mast step.

Here is a photo of the old mast step.  I knew from the get go that I had to unstep the mast and replace the step.  From what I have read this is a common problem with most LF38s.  The failing in C&C construction is that the center of the base was not well supported under the step.  The step rested on marine plywood, and over time wet plywood rotted away allowing the force of mast to push down and break the step.

Designing a New Mast Step

I looked into having a new mast step welded up from Aluminum angle stock like others have done. But I was told that it may be easier to have the mast step milled out of a solid block of Aluminum.  The idea was that while material cost would be higher, CNC milling is virtually labor free whereas welding is much more labor intensive.  Yes, much of the material is cut out, but it gets recycled.

Below is drawing from the 3D model of the mast step used to generate the CNC step file.  The mast step was milled the same day I dropped off the material.

CAD drawing of new mast step.

A solid block of 6061 grade Aluminum
formed the beginnings of the new mast step.

Mast step after CNC machining.

New mast step next to old broken step.

Mast step painted with several coats of epoxy paint.

Repairing the mast step support

1/2" structural fiberglass (FRP) board was used
to replace rotted plywood support.

Additional 1/4" FRP was added to build up
the support base before adding thickened
epoxy and leveling with the mast step.

Mast Step Installation with Coin

When I unstepped the mast I found a coin in the mast step. The coin was a 1976 U.S. Bicentennial dollar coin.  The practice of putting a coin under the mast has its roots in Greek mythology.  The theory goes that coins were placed there to pay the ferryman, Charon his fee for taking the departed across the River Styx to the afterlife should the vessel be lost.  While I'm not superstitious, I do like a good yarn, so I cleaned up the coin, stuck it down with a little sealant to the mast step.  Let's hope it's never needed.

Mast step installed with Bicentennial dollar coin just forward of the feel bolt.