Forums > Windsurfing General

Carbon Mast repair - South Coast NSW

Reply
Created by timmy201 Two weeks ago, 5 Nov 2018
timmy201
NSW, 24 posts
5 Nov 2018 2:05PM
Thumbs Up

Hi All,

I'm looking for someone who can repair my mast bottom section. It was my first time on the water in a couple of years and the first time using this rig. You can see where the collar here has separated from the bottom section, I just need to have a new collar ring bonded onto the bottom half. Apparently electrical tape was not strong enough to hold it together!


I'm in the Illawarra, I'm happy to travel a reasonable amount to get it fixed

Cheers, Tim

Mark _australia
WA, 18409 posts
5 Nov 2018 2:34PM
Thumbs Up

So that bit belongs where it is, just a little bit to the right?
And it has a taper to sit nicely on the mast taper?

If so I'd just clean it all up nice with metho, and stick it back on with JB Weld or a similar 24hr metal filled epoxy. Slight pressure with some tape to squeeze it inwards a bit as it sets.

It will be plenty strong enough as its taking a shearing load along the axis of the mast and something like JB Weld is insanely strong.

$20.

timmy201
NSW, 24 posts
5 Nov 2018 5:54PM
Thumbs Up

Select to expand quote
Mark _australia said..
So that bit belongs where it is, just a little bit to the right?
And it has a taper to sit nicely on the mast taper?

If so I'd just clean it all up nice with metho, and stick it back on with JB Weld or a similar 24hr metal filled epoxy. Slight pressure with some tape to squeeze it inwards a bit as it sets.

It will be plenty strong enough as its taking a shearing load along the axis of the mast and something like JB Weld is insanely strong.

$20.


Hi Mark,

The problem is the collar ring has split right through and is now a "C" shape, so it has no strength at all.

I am thinking either a new section of tube the right diameter could be bonded on, or perhaps a new section could be laid on to form the collar.

I did have my formula mast repaired 10 years ago and it's held up well, but I don't remember the name of the guy that did it.

wind012
WA, 73 posts
5 Nov 2018 3:05PM
Thumbs Up

What brand?

You can buy the mast collars as spares from North/DuoTone. No idea if the diameters will be compatible but they have different sizes.

Imax1
VIC, 1529 posts
5 Nov 2018 6:22PM
Thumbs Up

Because it's split , Id glue it in place then wrap a few layers of glass around it overlapping tha mast a bit.

wind012
WA, 73 posts
5 Nov 2018 9:04PM
Thumbs Up

by the way, the north/duotone collars are aluminium.

Mark _australia
WA, 18409 posts
5 Nov 2018 10:37PM
Thumbs Up

Select to expand quote


timmy201 said.. The problem is the collar ring has split right through and is now a "C" shape, so it has no strength at all. I am thinking either a new section of tube the right diameter could be bonded on, or perhaps a new section could be laid on to form the collar. I did have my formula mast repaired 10 years ago and it's held up well, but I don't remember the name of the guy that did it.




The ring only has to not slide down the mast.
The fact it is split means it will slide down easily.
However if it is bonded to mast and split glued up at the same time with plenty of JB Weld means it cant slip down (shearing force) thus stressing the collar split (in tension but it won't be unless the collar does slip down.)

To wrap with some glass and resin also would not hurt as per suggestion above.
Anyway I was suggesting its an easy home handyman job so you don't get fleeced. If you were here I'd repair it for next to nothing - its 10mins for one step and 10mins for the next - but I bet some random fibreglasser or boat place would sting you bad.

Or yes, if you can find a ring of aluminium it will glue on and work better but that could be hard to find, and certainly harder to find in a marine grade. Old section of broken mast maybe...

timmy201
NSW, 24 posts
8 Nov 2018 12:26PM
Thumbs Up

Thanks all. The mast is an old Sailworks 500CC which matches the 7.6 SX Racing sail I have. I just needed something a bit smaller to get on the water again.

What kind of JB Weld would be suggested, and is there any type of fiberglass kits that would suit a carbon mast?

The composite factory has quoted me around $100 for a professional repair which doesn't sound too bad?

Mark _australia
WA, 18409 posts
8 Nov 2018 10:27AM
Thumbs Up

Not the fast ones. Just normal 24hr JB Weld
Then sand it all lightly with 120g, wash and dry.
Wrap with about half a metre of fibreglass cut say 30-50mm wide and epoxy resin. Fibreglass resin would do. Lightly sand off any spiky bits

Imax1
VIC, 1529 posts
8 Nov 2018 1:50PM
Thumbs Up

This is what i would do.
Glue the ring in place with high strength Araldyte , small two tubes , Bunnings $ 12 . Only use enough to glue the ring . Let dry .
Buy some glass cloth 6oz to 10oz , auto place , $ 10 or so.
Cut glass strip 40mm wide . 600mm long . This will give you about four wraps .
Wrap with masking tape the area where the masts join , up to the ring . ( This is so no glue gets on the joining area ).
Mix the rest of the Araldyte .
With a small brush paint a layer of Araldyte on the ring and down the mast 20mm , ( total 40mm , the width of the glass strip ).
Wrap one layer around the mast and then paint over the first wrap and keep winding around and so on .
Keep the rest of the glue in one lump.
Wrap the repair in masking tape , ( medium tight ) , glue should squeeze out each end , ( doesn't matter if it doesn't ).
Keep an eye on the remaining glue and when it starts to harden , ( it gets like hard jelly or rubber ) , remove tape over repair .
With sharp blade , cut along top of ring down to the first masked off surface , it should cut through any glue overflow if u catch it before it gets too hard . If it is too hard , file it .
Remove tape .
Buy beer with the $ 78 you have just saved .

ps : Mark answered as i was writing this , same idea , could have saved myself some time , typing with one finger !

sailquik
VIC, 4137 posts
9 Nov 2018 3:08PM
Thumbs Up

On the same topic, but slightly different:

I was talking to a longtime sailor, board maker and fiberglass worker the other day who now runs his own sailboat repair business and is getting back into windsurfing with his two boys. Needing lots of sets of gear for the 3 of them, he has been scrounging up good used stuff and repairing it. The best is a high carbon NP race mast, broken in the boom area. Now most people would call that a write-off, they are very difficult to successfully repair, but he showed me the mast and has done a fascinating repair that has lasted very well for over a year to date. He made a very carefully fitted, tapered sleeve from another old mast that was a very neat fit in both halves and then used carbon uni and a vacuum bag to repair the outside. It is only 1- 2 mm thicker and looks great!

I have tried a similar repair in the past with less success. He emphasised, and I agree, that the key is to get the inside sleeve fitting very snug like a 2 piece mast ferrule, (tapered so it affects mast bend the least), and then to taper sand and repair with vacuum and carbon. It is a fiddly and finicky job for sure.

If I ever break another SDM mast, I know who I am going to see.

Mark _australia
WA, 18409 posts
9 Nov 2018 12:41PM
Thumbs Up

Just out of interest do you know how he tapered the inside of the sleeve? Lathe and sandpaper...?

Imax1
VIC, 1529 posts
9 Nov 2018 6:38PM
Thumbs Up

Trying to hold a mast in a lathe would be scary , the tail whip out the back would be biblical . Can be done though .
I did it once cutting 200mm off the bottom of a mast . I had to make a wooden bung with a hole , at the back of the lathe to hold it steady , It was a lot of effort and it was a big lathe. Your talking serious lathe size to have a 50mm spindle hole for a mast to go through.

sailquik
VIC, 4137 posts
9 Nov 2018 7:19PM
Thumbs Up

Select to expand quote
Mark _australia said..
Just out of interest do you know how he tapered the inside of the sleeve? Lathe and sandpaper...?


I think he said it was just sandpaper and elbow grease.

Pretty sure he didn't use a Lathe!

Mark _australia
WA, 18409 posts
9 Nov 2018 6:41PM
Thumbs Up

That's why I asked
to taper the inside of a mast section neatly would be not worth it I reckon.

sailquik
VIC, 4137 posts
10 Nov 2018 1:29PM
Thumbs Up

Select to expand quote
Mark _australia said..
That's why I asked
to taper the inside of a mast section neatly would be not worth it I reckon.


His reasoning was to reduce a hard point, or straight point in the mast curve.

I would use a rat tail rasp or file.

Mark _australia
WA, 18409 posts
10 Nov 2018 12:14PM
Thumbs Up

Sorry I meant not worth the effort. It needs a taper of course - but to do that inside a mast reasonably evenly with all the carbon splinters etc, what a mongrel job.
I'd make rod holders and buy a new mast.

I have a lot of carbon SDM rod holders

Imax we're taking about a short section a foot long ish. Yeah a whole mast would get scary.

Mastbender
1794 posts
10 Nov 2018 12:18PM
Thumbs Up

Or wind chimes.



Subscribe
Reply

Forums > Windsurfing General


"Carbon Mast repair - South Coast NSW" started by timmy201