Repair a bent boom?

[ProDave]

Our boat, a Hunter Horizon 23, has a bend in the boom. It was like this when we got it. I don't think it is in danger of failing, and it does not seem to appear to affect sailing (no difference noticed between port and starboard tack) It was not even very visible as our old stac pac enclosed the whole boom.

But now we are replacing the stac pac, the new one might be one that fits onto rather than around the boom, so the dent would be immediately visible all the time. so time to consider if it can be repaired. Some pictures.

The "dent"



View along the boom




The shortening effect of the lens makes it look worse in that picture than it really is.

Has anyone tried repairing this? Even if not a perfect repair it would be nice to make it a bit better.

My instinct is simply trying to bend it the other way might end badly.

 

[PabloPicasso]

Steel is very repairable, dents can be panel beaten etc. Aluminium whilst strong and light has much less impact restistance

You could try "panel beating" it and then reinforcimg it internally. Perhaps riveting a new bespoke internal collar to the existing boom.

There maybe such an item made by the OEM for just such a repair?

Otherwise its the cost of a new boom vs the cost a faffing about making a new internal (or I suppose, external) support collar.

 

[PetiteFleur]

You could try talking to a local spar/mast supplier and see what they say - or try a local aluminium fabricator?

 

[rotrax]

Not only is it bent and dented, it is also cracked.

Needs fixing...............................................

 

[Pinnacle]

It’s scrap. All IMHO.

 

[nevis768]

I wouldn't use it until I had it checked/repaired (if poss) by professionals. Easy enough to check by sending some photos to the relevant people. I imagine a failure while sailing could cause damage to other items or people close by.

 

[Minerva]

If it were me, I'd be looking to remove any fittings & end caps then sourcing another tube extrusion. I can't say I'd trust that.

Of course, it is only a wee 23fter so probably over spec'd for the loads it experiences, You may get away with a sleeve.

 

[doug748]

"My instinct is simply trying to bend it the other way might end badly."


I think so. A new boom would be expensive. Most satisfactory repair would be to source a new full length of extrusion and swap the hardware over. Or to improvise a repair with a similar scrap boom and chop the end off yours, fit an internal sleeve, etc.

Easy to say with 3 spar makers on my doorstep but not so for you. I might just live with it a little longer take full measurements, identify the section and keep my eyes peeled.

PS
Ah, I see Minerva beat me to it

.

 

[Chiara’s slave]

If you can’t tell one tack from another with that, you have some other problems. Possibly the nut on the end of the tiller. And yes, it’s scrap. But you’ll get a few quid for it, and a new one won’t be that expensive.

 

[dansaskip]

I agree with the others it is scrap. I wouldn’t go sailing with that .
You need a new boom section the fittings etc might be reclaimable/ reusable

 

[William_H]

Eek how could that possibly happen. Perhaps damage in storage. I have a friend with 22fter had a boom break during a short race. But that was in the vertical plane. I believe he reinforced it with a wood plug. Loads of course depend on where the main sheet and vang attach. Looks like your bend is near the clew. Not so less concern re failure compared to further forward.
You may be able to reduce the bend with brute force (in the fork of a tree.) Once having accepted a new boom may be in order. Incidentally I had great success with a new boom made from a broken carbon fibre dinghy mast. But of course a round boom would not be so easy for stack pack. It is about half the weight of the original so much nicer when it hits your head. ol'will

 

[garymalmgren]

Really no need for a NEW boom, but a replacement would be wise.
You can search for a used boom by shuffling around some marinas and boat yards and put the word out or you can advertise for "Used Boom wanted".
Masts for Sale in Scotland | Gumtree


I am sure there is one sitting around just waiting.
Anything overlenght can easily be cut to length.

gary

 

[fredrussell]

Agree with Gary ^^^
Any boat yard will have a few old spars knocking around.

 

[Chiara’s slave]

Just visit a dinghy club and ask around. Bound to be a few old masts someone would like a very small fistful of cash for.

 

[Poignard]

You could try talking to a local spar/mast supplier and see what they say - or try a local aluminium fabricator?

That's what I would do.

In fact that's what I did when my boom snapped in two off the French coast a few years ago.

A local aluminium fabricator said he could repair it but, as my insurers were paying, I opted for a new boom.


If you don't get a high quality repair, or a new boom, when you come to sell the boat the prospective buyer's surveyor will most likely condemn it so you might as well pay now as it will only cost more later.

 

[Daydream believer]

Re the stack pack bag. Instead of going under the boom, may I suggest an alternative.
Caravan owners use awnings & these slide into a "P" shaped section. I have one of these each side of the boom & the cover fits into that. It keeps the underside of the boom free & does not have the problem of going in the same groove as the sail. It is just pop riveted to the side of the boom.
track

 

[Chiara’s slave]

Re the stack pack bag. Instead of going under the boom, may I suggest an alternative.
Caravan owners use awnings & these slide into a "P" shaped section. I have one of these each side of the boom & the cover fits into that. It keeps the underside of the boom free & does not have the problem of going in the same groove as the sail. It is just pop riveted to the side of the boom.
track

Good thinking. It gets around the need to have a specialist boom extrusion, with track top and bottom. I tend to forget this, as my main is loose footed.

 

[ProDave]

Thanks for the sensible replies. I almost gave up on the thread at the unwanted nut on the tiller comment. I thought this forum was better than personal insults. If it happens again I will report that user, most uncalled for.

The boom was like this when we got the boat. I am sure the damage happened off the boat, I just cannot see anything the boom could violently swing against in situ to do that. In spite of the bend and small crack I an sure is is sound for the job. It would be of course a totally different issue if this damage was on a mast.

I contacted the original manufacturer, that profile is no longer made so the option of buying a spare length of extrusion is not possible, and they quoted just over £1000 for a new boom with the current profile and all the fittings. That is too much of a fraction of the boats value to be viable.

We are looking for a second hand replacement boom. So far no luck. We are prepared to do alterations to a different boom to make it work, for instance the reefing lines run inside this boom, a different boom may necessitate bolting blocks on either side to run reefing lines externally. If anyone hears of a boom about 3M long for sale let us know.

The dinghy club idea may be worth a try, are you there suggesting we use a section of a damaged dinghy mast? I can't imagine many dinghy booms being big enough.

I posted the question about straightening the existing mast to see if it was possible, A simple no it is no rather than ridicule would have sufficed.

We will continue using it until we find a cost effective replacement. One option we might try is loose footing the main sail and try it like that.

The stac pack is not decided yet. We might opt for independent lazy jacks and a simple sail cover instead.

 

[Stemar]

Thanks for the sensible replies. I almost gave up on the thread at the unwanted nut on the tiller comment. I thought this forum was better than personal insults. If it happens again I will report that user, most uncalled for.

From the poster's other posts, I'd say it's highly unlikely that it was meant as an insult. Gentle teasing is far more his style.

As for the boom, I'd agree with those who say a replacement is the ideal fix. I'm no metallurgist, but I suspect that a brute force attempt to straighten it is likely to make matters worse, quite possibly closing the slot for the sail and weakening the boom still further.

When I put a home brew stacpak on my 24 footer, the slot was too narrow for both the sail cover and the sail, so I simply took the sail out, leaving it loose footed, and made a simple webbing band that went through the clew eye and round the boom to hold it down. I also beefed up the outhaul, all of which actually gave me better control over the sail shape.

 

[Chiara’s slave]

I am sorry, Dave, it wasn’t meant as an insult. But your sail will be seriously different on different tacks, I cannot understand how you don’t notice. And yes, cutting up an old mast is what I would try.