Started on a job today to find a persistent leak into the boat from somewhere in the mast step on the Cole 23.

After removing many, many layers of goo, I found that there was a (very) small pulley set into the deck in the middle of the mast step. The orientation suggested that it was to tension something inside the boat. It would appear it was the source of the leak. Any ideas what it was doing?

So I took the mast step off completely and it is not a pretty sight. Is it just a case of filling the holes with Epifill (or similar) and redrilling the bolt holes, or is this a bigger job than my limited skill set with fiberglass?

There are no stress cracks inside the boat under the mast step, so it all looks good from that angle. I have now cleaned up the alloy mast step and it is looking good.

Could have been for electric cable albeit those type of pulleys are typically used for small diameter 7x19 stainless wire and could damage an electric cable. If it is not needed for anything suggest fill the pulley hole with high strength epoxy filler as you say, and a layer of woven or biaxial glass and epoxy resin over the top and under if you can. Fwd and aft of the mast step are gelcoat cracks which all boats of this age have, but they could be symptoms of a compressed (a bit shorter than at the original build)) internal mast compression post. This should be easily determined by a straight edge and visual sighting on top and below. If the compression post is compressed this is easily rectified with a suitable very hard packer under the mast step and on top of the compression post - or if easier on the lower and of the post where it sits on the keel. What to make the packer out of would depend on the thickness needed - if only a few mm then stainless plate, if more then maybe very hard timber shim. Have to make sure that the compression post landing internally under the deck head or on the keel is suitably located and restrained laterally and fore and aft so that it doesn't pop out sideways or fore and aft when you re-step. Suggest acetone flush clean out the gelcoat cracks on the deck, fill with Septone marine polyester filler and paint touch up.

r13 said..
Could have been for electric cable albeit those type of pulleys are typically used for small diameter 7x19 stainless wire and could damage an electric cable. If it is not needed for anything suggest fill the pulley hole with high strength epoxy filler as you say, and a layer of woven or biaxial glass and epoxy resin over the top and under if you can. Fwd and aft of the mast step are gelcoat cracks which all boats of this age have, but they could be symptoms of a compressed (a bit shorter than at the original build)) internal mast compression post. This should be easily determined by a straight edge and visual sighting on top and below. If the compression post is compressed this is easily rectified with a suitable very hard packer under the mast step and on top of the compression post - or if easier on the lower and of the post where it sits on the keel. What to make the packer out of would depend on the thickness needed - if only a few mm then stainless plate, if more then maybe very hard timber shim. Have to make sure that the compression post landing internally under the deck head or on the keel is suitably located and restrained laterally and fore and aft so that it doesn't pop out sideways or fore and aft when you re-step. Suggest acetone flush clean out the gelcoat cracks on the deck, fill with Septone marine polyester filler and paint touch up.

This is the Septone gelcoat filler I meant.

www.whitworths.com.au/septone-gelcoat-repair-putty-400g