Mast step rebuilt
In case anybody's wondering, I'm replying to my own posting incase someone else has the same problem. The original mast step appeared to be 4 pieces of 1/2" plywood bonded together and laid across the bilge sump like a bridge. The wood was poorly, if at all, encapsulated. After years in the wet of the bilge, it finally gave way. On top of the step was a box built of 2x2 aluminum channel. If doing this job, you should first mark the position of the box and measure the height of the old step. An easy way to do this is simply measure from the mast collar down to the step. If the step has collapsed, a best estimate of where it was should be made. After chiseling out the old step, a new step was created by placing a piece of cardboard across the bilge and applying alternating layers of glass matt, cloth and/or roving for a solid composite step. The new step is about 3 1/2 inches thick. Room must be left for a bilge pump suction hose or bilge pump if used. The front of the step should not block drainage from the forward part of the boat. The aluminum box was remade and a 1/2" aluminum plate was added underneath to break up a perceived shear plane where the edges of the box lined up with the vertical sides of the bilge sump. The plate and box were bolted to the step. The mast was restepped.
