Hello all,
On a similar but more detailed note, how did you get the mast cap off? I want to foam my mast with a spray, but the cap seems bolted to the mast. So before I come up with my own way and breaking it, is there a special tool or technique?
I let a "pro" take my mast cap off. It's a very simple job from watching him. First, he drilled out the 2 rivets (one on each side. The cap is a very tight fit. He then lightly tapped on the cap and the side of the mast to work it off. I'll let the experts tell what to do next for the replacement options. My guy put in 2 new rivets. I think you can rent a rivet gun at any tool rental yard.
You probably could also get by with a couple of sheet metal screws in place of rivets. Now to your reason for removing the cap. I also elected to foam. I got some stuff at Home Depot. I didn't have a lot of time as I was interrupting the workman. So, what I did was stuff some newspaper down the mast to act as a "stop" for the foam. I then gave the mast a shot of foam, stopping about an 1"-1.5" from the top. Big mistake! The mast cap was then replaced and I pulled the boat back home. When I got home, I took a look at the cap and was shocked to see that the foam had expanded through the hole in the bottom of the cap and was engulfing the sleeves (wheels). This whole procedure was to replace my mast cap that had frozen sleeves.
I quickly grabbed my WD40 and sprayed the wheels along with digging out as much of this foam as I could. Luckily it was still in the semi-sticky state. I was able to clean out all or most of the foam that squeezed by the hole in the mast cap. If I had it to do over, I would have jammed the newspaper further down the mast and the sprayed foam down to maybe 3" or more from the top of the mast. I would then have jammed a couple of pieces of cardboard down on top to help prevent the foam from going through the top of the mast.
I read somewhere here that Hunter was now using solid mast caps, but I don't think that's true as I used a new mast cap that I ordered from Hunter about 3 weeks ago.
Anyway, if you have a hole in your mast cap, be very careful about foam coming through it and freezing up your halyard wheels.
I suspect that I have a totally sealed area in my mast cap now.
A further note to anyone "turtling" close to shore. My boat is a '08 model that the original owner only kept for a few months before returning it to the deal for a consignment sale. I suspect he turtled the boat, driving the mast into the sand. There was a lot of sand in the mast cap that froze up my sleeves. Nothing I could do would free them up. Hence, the reason for the new $35 mast cap from Hunter.
The moral is that IF you do turtle into the sand, you should try to clean the mast cap out immediately to prevent frozen sleeves.