need a new mast

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scotwing

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Aug 25, 2011
2
Oday daysailer backyard
Just bought a Daysailer 2, 16'9" length. The mast is bent and I'd like to make or get a new one. I looked at getting aluminum extrusions from Rig Rite that have the same section as the old mast, then re-attaching the hardware. But many of the attachments use rivets that I have no experience in using. Can I order a new mast to original specs, or do marina shops make these for you?

Also, the boat specs say the mast is 24'11", but I measure 21'11". Do the specs include the mast section inside the hull, or was my mast shortened at some point in its life?

Thanks for your help.
 
Shoaldrafter

Shoaldrafter

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Dec 8, 2006
1,085
Oday 26 Starr, SC
new spar

scotwing said:
Just bought a Daysailer 2, 16'9" length. The mast is bent and I'd like to make or get a new one. I looked at getting aluminum extrusions from Rig Rite that have the same section as the old mast, then re-attaching the hardware. But many of the attachments use rivets that I have no experience in using. Can I order a new mast to original specs, or do marina shops make these for you?

Also, the boat specs say the mast is 24'11", but I measure 21'11". Do the specs include the mast section inside the hull, or was my mast shortened at some point in its life?

Thanks for your help.
Click to expand
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You mentioned rig rite: http://www.rigrite.com
Have you asked them for quote on complete and put together mast ready to sail?

Have you consulted with Cape Cod Shipbuilding?
http://www.capecodshipbuilding.com
Mr. Goodwin, President, can be talked to directly and they have a spar making division.

And there is Dwyer Mast in Connecticut:
http://www.dwyermast.com/

Understand that the price of Aluminum has followed the price of gold. What used to cost $500.00 now cost $3,500.00 and maybe more.

Shipping a mast is a big issue. Are you near enough to go get it yourself?

Also, there is
http://www.z-spars.com/zspars.html
Although they do not say so, they have a plant in Florida.

Why not make a wooden mast? Do you have table saw? get pieces of clear wood and laminate with epoxy to duplicate your original mast. After you laminate to length and cross section thickness use draw knife to carve to shape and sand smooth. Laminate with layer of glass and fair to final shape.
You would get a lot of attention...

Ed K

 

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Barnacle Bill

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Jun 9, 2008
1,801
- -- -Bayfield
If you are not comfortable retrofitting the hardware from your old mast to the new one, a good boat yard should be able to do it for you. You can also order the mast through them and let them do the measuring for you, etc. That way the worry is not yours. Pop rivets require a pop rivet gun, which you can buy at most any hardware store. Ask how they work and you will see how simple they are to use. You don't have to use rivets, you can also drill and tap holes for machine screws, if you prefer them. If the pop rivets you are using are stainless, then they are harder to work with so you might need a heavy duty rivet gun. If you measure everything carefully from your old mast and mark the spots for hardware on your new mast, you can do this work yourself unless you simply are not good with tools. I would not rely on boat specs as some manufactures make changes. You need to buy a duplicate of what you have including the part inside the boat if it is keel stepped. Sometimes a manufacturer will only sell you a blank section based on their stock. That means you buy the mast that is at least as long as you need and then you cut off the unneeded part with a hack saw (use an aluminum blade). You can cut the sail entry slot with a router, but you don't want to make a mistake or you might ruin the mast. If you don't feel comfortable doing this, ask the mast manufacture to cut that slot for you. The charge is not that much. You will have to give them the exact location of the slot and how long it is.
 
Sunbird22358

Sunbird22358

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Jun 2, 2004
1,944
Oday Day Sailer Wareham, MA
24' 11" is the "full" mast including the part below deck. The older models (prior to about 1981) had the mast stepped through the deck (cuddy top) and the mast was one piece to the cuddy floor. (Mine is that way, 1979 model) Newr boats have a hinged maststep and the part below deck is fixed in place. O'DAY never updated their specs in the brochures after switching to the hinged mast. Some of the older boats did come fro mthe factory with a hinged added, but the mast part below deck was not permanently installed, just held by a pin through the mast and step.

D&R Marine sells a replacement mast, as does DWYER, and ZEPHYR (Cape Cod Shipbuilding). Dwyer will even sell the new mast as a "kit" to be assembled by the owner, not sure how much price advantage though. RIG-RITE is a good source as well.
Shipping is always the big "killer" in spar prices, if you are close enough to any of the above you should be able to pick up the mast at their location. I keep my boat only 2.5 miles by water from ZEPHYR........ guess which place would be my choice? D&R is only 30 minutes by car........ could tow trailer to there....... all comes down to price if I ever needed to get a new mast or boom!
 
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