Common mast problem
Mast step problems of that type are common simply because water does get in from the four bolts horlding the mast tabernacle (that is the name of the metal hinge holding the mast, not one of these words that us French Canadian use while insulting each others ;-). So the problem exist because the bolts were not properly sealed with marine grade sealant. If it was just slightly craked, there is some product called "Creapy crack sealer" or something like that. If it went down 1/4 inch, it's rotten and must be fixed. To fix this, you must drill some holes, get the rotten balsa core out, and pour epoxy in there. Some would drill holes on each side and then try to do this ... but then the holes will show unless you repaint the whole deck! I suggest removing the tabernacle, plugging the 4 holes from underneat (well plugged in and add a container underneat to collect epoxy in case). Now it depends on the extent of the damage. There are 2 cases: 1- There is some rotten balsa around the 4 holes. Use a piece of bent metal (yes, a coat hanger works) and get the rotten balsa out as far as it goes. 2- It is quite rotten and you can't get it all out with the coat hanger. Then drill two 1" holes in the center of where the plate fits. Make sure you don't drill through, just cut the upper fiberglass layer. You can also use a drimmel type of tool, but again ... just the top fiberglass layer has to go. The trick is to do this such as to be able to hide the repair under the tabernacle once it's back in place. Then you scrape the rotten balsa from out there as far as it is rotten. Whatever the extent, you let the thing dry completely and then pour epoxy in there to fill the void. To be sure it is dry, use a fan for a few days. If it is not dried to your liking, pour acetone in there and suck it out. Do that a few times, and let dry. Water is soluble in acetone, and acetone will evaporate better than water. If it did sink a lot (1/4" is a lot) you can force in some pieces of teak wood to "lift the fiberglass back up". Don't fill it completely with wood, just a few pieces to get it back to normal level. Then fill it with epoxy. Epoxy can be poured in there in several coats, it does not matter. In fact, smaller layers ensure that there is not a large thermal expension while the epoxy polymerizes (actually, polymerization makes it denser, so it should shrink, but thermal expansion makes it larger ... I think they migh cancel out!). Remember to ensure that it is not pouring inside the boat!!! Epoxy, not fiberglass should be used. Buy the liquid version not the paste. Once it cured (a few minutes or hours depending on the produce) just drill back the 4 holes and sand the thing flat. Use marine grade adhesive/sealant to make sure water wont get in again. Note that now it is epoxy, so it won't rot anymore. Ho, yes, purists would add that you just added a little weight to your boat! I think 6 ounces of epoxy is lighter that wet rotten balsa ;-) I have done this on a two boats, and never had any problems after. Hope this helps. P.S. You still use the "Creapy craks" thing on the craks after that job. Take pictures of what you are doing to show to the next buyer so he/she knows what a good repair job youve done ;-)
