sailoppopotamus
Active member
I have unstepped my mast for a full re-rig and repairs to the mast-step. With the mast down I've had the opportunity to inspect it carefully and discovered two broken spreader brackets are cracked/broken. Here is a picture of the part:
Before I go around asking machinists/welders for their opinions I'd like the forum's input on what a reliable repair might look like. The part looks like cast aluminium. In assessing my options I've come up with the following:
1. Just get the break welded: I imagine this can be done, but will the fix be strong enough? I imagine the part will have to be anodized to protect the weld.
2. Get the part welded, and get the welder to fill the circled area with material. Again, I'll probably need to get the part re-anodized.
3. Get a machinist to make me aluminium inserts that fit with some precision into the circled area. Get the inserts anodized and glue them with 5200 or something into the circled area to add strength. This has the advantage that I won't have to remove the remaining three brackets from the mast, and allows me to reinforce the remaining two brackets that haven't cracked (yet).
4. Fill the circled area with epoxy or something, and get new pieces cast and anodized. A friend of mine tried this with his stanchion bases (sand casting), and the resultant parts were of rather low quality and needed significant rework (welding & lathing) to make them usable. However this approach looks like it might yield "better than new" parts, reinforced in the weak spot, if the casting is done well.
Regarding replacement: I have talked to ZSpars UK who have been very responsive and keen to help (thanks Matthew!), but unfortunately don't have spares to supply. I am still trying to track down new/used parts from other sources. However, the fact that two out of four brackets have these cracks points to a design weakness that is likely shared by any replacement parts. It's a 40 year old part, so it's done pretty well for itself, but perhaps a good repair in this case will make it stronger than it was originally.
Before I go around asking machinists/welders for their opinions I'd like the forum's input on what a reliable repair might look like. The part looks like cast aluminium. In assessing my options I've come up with the following:
1. Just get the break welded: I imagine this can be done, but will the fix be strong enough? I imagine the part will have to be anodized to protect the weld.
2. Get the part welded, and get the welder to fill the circled area with material. Again, I'll probably need to get the part re-anodized.
3. Get a machinist to make me aluminium inserts that fit with some precision into the circled area. Get the inserts anodized and glue them with 5200 or something into the circled area to add strength. This has the advantage that I won't have to remove the remaining three brackets from the mast, and allows me to reinforce the remaining two brackets that haven't cracked (yet).
4. Fill the circled area with epoxy or something, and get new pieces cast and anodized. A friend of mine tried this with his stanchion bases (sand casting), and the resultant parts were of rather low quality and needed significant rework (welding & lathing) to make them usable. However this approach looks like it might yield "better than new" parts, reinforced in the weak spot, if the casting is done well.
Regarding replacement: I have talked to ZSpars UK who have been very responsive and keen to help (thanks Matthew!), but unfortunately don't have spares to supply. I am still trying to track down new/used parts from other sources. However, the fact that two out of four brackets have these cracks points to a design weakness that is likely shared by any replacement parts. It's a 40 year old part, so it's done pretty well for itself, but perhaps a good repair in this case will make it stronger than it was originally.
