After a few weekend trips to the Owner's Catalina 36, here is the finished Mast Boot made from 40 oz Hypalon; see below posts, 3 pics.
Later tonight I can upload more pics of the process and installation. It took longer because everything had been sealed in silicone and was leaking. We re-bed the mast collar in butyl tape with new hardware before starting on the actual mast boot. Time consuming to scrape away all the silicone but worth it for a leak free seal. The owner is very happy with the end result. I'm glad I pulled off without any major pleats or wrinkles, but you can see there is a bit of light waves to the fabric. Very hard to get the perfect shape when not dealing with a round mast.
Later tonight I can upload more pics of the process and installation. It took longer because everything had been sealed in silicone and was leaking. We re-bed the mast collar in butyl tape with new hardware before starting on the actual mast boot. Time consuming to scrape away all the silicone but worth it for a leak free seal. The owner is very happy with the end result. I'm glad I pulled off without any major pleats or wrinkles, but you can see there is a bit of light waves to the fabric. Very hard to get the perfect shape when not dealing with a round mast.
