I talked with multiple riggers, and they said the cost to fix would likely rival the cost of a new mast. They said the repair would likely involve adding a sleeve and welding, and that would be spendy. I'll spend some time looking for a used mast, but I'm not sure how to shop for one. I'll likely talk to a rigger to see about my options for new/used mast.
I think these boatyards take the conservative approach, because if they said a mast was ok and then it failed in heavy winds and somebody died or was seriously injured, that would be bad for everyone. They're giving their strong warning that they believe the mast is unsafe and I'm taking full responsibility if I don't replace it. They said masts are regularly replaced due to cracks or grooves. The boatyard has refused to work on the mast due to the condition.
If insurance really falls thru, I'm looking at a few options:
1. Don't fix the mast or deck, and have the boatyard reinstall and seal up everything and launch the boat without any repair. With this approach, I might be ok if I limit sailing to light winds. My deck isn't really crushed (really only wet wood and delamination at the step), so it's possible that I could just dry it out and leave it as is (boatyard said this could work). The boat would become a daysailer for the nice days, and it would be a powerboat and live at the dock the rest of the time. I'd never take it far from the marina. The mast repair has been there for years without an issue so far, and it's possible it could go more years with no issue, so long as the boat isn't pushed. This is risky, as that spreader could fail, and there's no way to know when. I'm pretty skeptical on this approach since the yard was pretty firm on the poor condition of the mast.
2. Toss the mast, seal up the hole, and live on the boat as a powerboat. Never use it as a sailboat again. Basically, a floating condo for liveaboard use only. This is pretty lame since the living space is tiny, and it's not really cheap v a micro apt of the same size. The only perk of a sailboat to me is actually sailing....I'm not too interested in this option. Perhaps I could sell it for a cheap amount, somebody out there might be interested in simply having a boat to live on without actually going out.
3. Sell to a scrapyard. Possibly strip off what I can. This is looking like what I'll most likely do at this point.
Here are repair costs I'm looking at now (my boat is worth about $20k):
- Mast Replacement: $15k-$20k
- Deck repair (per boatyard estimate): $6k
- Paint stripping: $5k
I'll take this as a learning opportunity. This was my first boat, and I'm not sure I'll want to do this again. I'll definitely spend some years doing research before I purchase again, if I do. I think the Hunter 31 has some unique issues with the rigging that make this boat a challenge (and costly to fix), so I'd like to get something that's more like the Toyota Corolla of sailboats with a simple setup and easy/cheap fixes for issues that come up. I'll definitely wait to get an excellent surveyor, and I'll be sure to pay a rigger to climb the mast to inspect everything.
What is the Toyota Corolla or Honda Civic of sailboats? Something cheap, reliability, and easy to fix. Cruiser only, never going more than 2 days trip from the marina.