H23 Mast Foot repalcement

[smitch13]

I'm the new owner of a 1990 H23. It was missing a jib halyard so when I lowered mast to fish it, I found the mast foot was broken. The new one arrived, but they don't match exactly and I had to cut out a chunk to get it to fit. Other people on the forum have had a similar problem and did some grinding with out apparent problems.
My problem is now when I went to raise the mast my head stay was 6-8" to short. Before it was getting close to being fully tightened. All other stays were slack. Headstay was straight and fitted correctly. When I did the dry fit on the foot, it seemed to fit flush and tight. The foot is flush with the mast as well. No debris in the step.
My only ideas so far are, I did not dry fit the foot with the bolt inserted and I didn't check the depth on the bottom although dry fitting should have seen an issue there.
Any other ideas on what to check for would be greatly appreciated.
Thank you

 

[rgranger]

This may be a streatch but....Going back to some basic geometry... a-squared + b-squared = c-squared. Your forestay is “c” in this process. Is the new foot shallower than the old one? If so your mast may be sitting 1/8” lower thus shortening “b”. Or maybe the ears on your mast foot for the pin are a little longer than your ears on your old mast foot thus shortening “a”.

?????

 

[isaksp00]

Yours looks like mine. You should be able to verify that the bottom of the mast extrusion sits right down against the base of the new foot, and measure the distance from the bottom of the extrusion to the center of the holes for the pin. Compare this to the same measurements on the old foot to verify the mast would sit the same vertical distance above the deck. Are the bottoms of the old and new foot identical so they sit the same distance above the tabernacle? If so the mast must be pretty much the same height. Is it possible your forestay fitting at the top where the eye fits into the clevis pin is twisted so it shortens the stay - looking at it should make that obvious if so. Does the mast look like it's vertical after you raise it, in the position where the stay doesn't reach far enough? The slack sidestays might mean it hasnt been pulled forward enough. Do you have a furler?

 

[Crazy Dave Condon]

Looking st the two I see some differences. Can you advise which mast you have as it would either be a Kenyon Isomat or Z Spar. I could not make out the number on one of them

 

[smitch13]

Sorry been a rough couple days.
It is a Z Spar, part 1096 on both and no furler. All the stays were straight. The mast was not getting fully vertical, at least my helper seemed to be struggling with more than they should have been. After removing the foot from the mast again and placing it on the step, the bolt holes lined up with out a problem, but the nub on the front end seems to be a bit to long and it would rock side to side a little bit. It looks like it was shifted only a degree or so, but figuring arc length, that's could be the 6" I was short and it not being vertical. Hopefully I will get some time in the next couple days to grind some of the nub down so it's actually flush.

 

[Crazy Dave Condon]

Before you do that how about some photos to get a better understanding because I am confused.

 

[smitch13]

I got the mast up with a bit of foot work. It's really hard to see in the pics, but the circled portion extended out just a bit. It was also rounded not flat. In the second pic there's a bit of a gap on the left (forward) when compared to the right (aft) side of the pic. The circled nub was just long enough to tilt the mast back far enough that I couldn't attach the headstay.

A couple minutes with a hand file and it was flush. The material is really soft so glad I started with a hand file and not a grinder.
That was yesterday and today I was sailing.