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Mast Cabin Deck Insert Damage
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Hi Bud


I'm so impressed and thankful that you have all jumped in with great advice. The ideal of a mold is very clever and I'm sure the finished product would have clean lines and be strong.


As you have suggested, step one is to explore the extent of damage beyond what is clearly visible, and I will go from there.


Thanks again for welcoming me to the Ensign Class.

Hi Zeke


Yes - this is Stephen Still -- but in contrast to the musician, no talent, less money and no "s" at end of name.


Sounds like fine advice -- and endorsement that this is worth looking after so it doesnt degrade further.

Steve,

I hope this doesn't make a mountain out of a molehill, but here goes...

In many peoples' opinions, 'exploratory surgery' is always required on fiberglass damage. IMO, it's the most important step. There is no way to know the extent of the damage until all cracks in the damage have been removed through poking, prodding, prying, grinding, etc... causing the least additional damage possible.... until nothing remains but undamaged original material.

Follow Zeke's most expert advice. He was the original owner of Ensign Spars, was the class builder for years, and obviously 'knows his stuff'.

I have a small offering which might help. Building a quick, positive mold is something I would consider and it might further minimize the clean-up and help shape the repair. Depending on the need after 'exploratory surgery' a positive mold can be made using some stiff, crunchy foam or even WetFoam, both of which are cheap and found at Michaels craft stores. WetFoam is not actually wet when you buy it, it's just named that because peeps use it to create flower arrangements and it does hold water very well. When you buy it, it is quite dry, and quite formable just with your hands or even by 'jamming' it into any particular shape for really accurate conformity. There is an article on pedestal repair on the ECA website that uses this technique:


I'm imagining two pieces of foam to form your mold. The first is produced by simply jamming a block of this foam into the foot of your mast. (Might need to poke a hole through the block first and insert a backed-up extraction cord for removal.) The second is formed by pressing a piece of foam into the recess on the ceiling inside the cabin. Put the two together with toothpicks, wrap it in cling wrap for a release agent, and voila, you have a really quick and easy mold for your work.

Tape off the area on the ceiling to catch drips and runs, and catch the epoxy when it is soft-cured to easily cut runs with an exacto blade to reduce or eliminate sanding.

Best of luck!

Is this really Steven Still?,

We call it the mast hole. I would get a small sanding disc for your
cordless drill and sand out as much as you can.
Build a damn with tape or cardboard on the inner hole to stop any
resin from going in the hole. Then tape the circle you want to stop
any resin from going on the deck.
I'm afraid you will need to glass as much as you can which is not
much. once cured sand again to the shape your happy with then I would
use some marinetex smooth out the best you can to fill in any
imperfections. I use wax paper or a plastic baggy cut to size, going
right over the wet marinetex. Your can form it with your hands and not
get in on you, once your happy let it cure and just peel off the wax
paper and it should be smooth with no sanding.
Wax paper will help in the curing process.

Zeke



Hi Rick


I appreciate the quick response.


Can I just do the epoxy step, sand it down, and forget the gelcoat step - since cosmetics aren't important if it hides under the boot ? I have some experience with west system epoxy - but havent done gelcoat.


thanks again - Steve

That’s a pretty straight forward repair. Much of it is just gelcoat. The weight of your mast is on the mast step and not the cabin. That is more of a pass through. I would clean up any loose pieces, layer on some epoxy to shape it and fill in with gelcoat. You may want to grind it back a bit to make sure there aren’t any cracks extending into the cabin roof that will make it unsafe to stand on. Find a good mast boot and it doesn’t have to be neat.

Hello All


Sorry I dont know the correct technical term for where the mast inserts into the deck above the cabin.


I'm a relatively new Ensign co-owner (and registered with the Ensign Class), and I found this damaged condition after the marina pulled the mast. See photo that I hopefully attached properly.


I have some limited experience with re-glassing, and thought I would try to mold some layers around the damaged edge.


Any advice appreciated on best means to accomplish this -- or if I can forget about it and just go sailing in a few weeks.


thanks

Steve

Chautauqua Lake NY






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