Mast is in backyard

[PGIJon]

Mast Cracked & Painting Advice

Had to take the mast down due to a crack that has developed on the mast just aft of the lower starboard spreader. (See Pic) While it's down I want to repaint the mast. Any thoughts on prep? Do I need to take it down to bare metal? Also replacing everything on top of the mast and rewiring.

As far as the crack goes. I'm having a U shape collar manufactured. We will remove the spreaders, Weld the collar on and then re-weld the spreaders back on.

Thanks in advance for your thoughts and ideas. -Jon

 

[Tantor]

I would consider riveting instead of welding.
Welding will weaken the aluminum.
To make this strong I would cut the mast and insert same profile inside the mast and riveted. Same way is mast extended by Mast builders….Outside surface will stay clean this way.