R
Russ Colombo
Structural Failure
The boat: a 1985 Hunter 40, owned since new. The scene: close hauled northbound, 0200 hours, 18 miles left to go of a 94 mile sail from Key West to Marco Island.The wx: stalled cold front, rain, north wind 20-25 knots, seas 6-8 feet.Mast failure occurred about eight feet up from deck. Boat immediately threatened to broach. Started engine only to have the failed rigging and sails drawn into the prop rendering engine useless. Cut away all rigging before it was able to hole the hull. Lowered anchor and by sheer luck, the CQR dug in at the end of 200' chain & rope rode in 60' of water, turning the bow safely into wind & waves.It was now time to get help, as we were engineless as well as dismasted. With my emergency antenna attached to ship's radio, I raised Fort Myers Coast Guard station about 60 miles north of my position. They dispatched a helicopter that, upon arriving overhead, asked via marine VHF if air evacuation was desired. I declined, instead asked the pilot to contact TowBoat US at Marco Island, as I had unlimited towing coverage with them. This the pilot was able to do; however he was told that TowBoat US policy prohibited them from responding to any calls in sea-swells exceeding five (5) feet! The helicopter pilot then suggested the Coast Guard could have a cutter on scene in about four hours' time, to which I agreed. The cutter arrived as expected, took us in tow for about four hours into the calmer waters of Marco Island, where the tow was transferred to TowBoat US.Subsequent investigation into why the mast failure had ocurred resulted in a surprise finding. The port shroud of the B & R rig terminates internally of the mast with a stainless steel stem-ball swaged unto the cable end and then pulled down against a stainless steel bearing cup. In this case, the bearing cup had been installed in a cocked position, resulting in the stem-ball bearing against half the s.s. cup and half against only aluminum. It took about 12 years of this condition for the aluminum to elongate sufficiently to allow the stem-ball and shroud to finally pull through, causing the mast to collapse. Because of the internal location of this design (no longer in use) it was impossible to discover the impending failure, even though the entire rigging had successfully undergone professional inspection only twelve days before it failed. I strongly recommend any owners of earlier model Hunters, circa 1985, to check whether their shrouds terminate INSIDE the mast. If so, you should have the terminal points undergo specialized inspection by whatever means your professional maintance provider offers. If at all possible, replacing the shrouds with EXTERNAL tang fittings would be an extremely prudent action.In my lucky case, no one was injured, the mast has been replaced (with EXTERNAL tangs)and the good vessel is as good...no BETTER, than ever!
The boat: a 1985 Hunter 40, owned since new. The scene: close hauled northbound, 0200 hours, 18 miles left to go of a 94 mile sail from Key West to Marco Island.The wx: stalled cold front, rain, north wind 20-25 knots, seas 6-8 feet.Mast failure occurred about eight feet up from deck. Boat immediately threatened to broach. Started engine only to have the failed rigging and sails drawn into the prop rendering engine useless. Cut away all rigging before it was able to hole the hull. Lowered anchor and by sheer luck, the CQR dug in at the end of 200' chain & rope rode in 60' of water, turning the bow safely into wind & waves.It was now time to get help, as we were engineless as well as dismasted. With my emergency antenna attached to ship's radio, I raised Fort Myers Coast Guard station about 60 miles north of my position. They dispatched a helicopter that, upon arriving overhead, asked via marine VHF if air evacuation was desired. I declined, instead asked the pilot to contact TowBoat US at Marco Island, as I had unlimited towing coverage with them. This the pilot was able to do; however he was told that TowBoat US policy prohibited them from responding to any calls in sea-swells exceeding five (5) feet! The helicopter pilot then suggested the Coast Guard could have a cutter on scene in about four hours' time, to which I agreed. The cutter arrived as expected, took us in tow for about four hours into the calmer waters of Marco Island, where the tow was transferred to TowBoat US.Subsequent investigation into why the mast failure had ocurred resulted in a surprise finding. The port shroud of the B & R rig terminates internally of the mast with a stainless steel stem-ball swaged unto the cable end and then pulled down against a stainless steel bearing cup. In this case, the bearing cup had been installed in a cocked position, resulting in the stem-ball bearing against half the s.s. cup and half against only aluminum. It took about 12 years of this condition for the aluminum to elongate sufficiently to allow the stem-ball and shroud to finally pull through, causing the mast to collapse. Because of the internal location of this design (no longer in use) it was impossible to discover the impending failure, even though the entire rigging had successfully undergone professional inspection only twelve days before it failed. I strongly recommend any owners of earlier model Hunters, circa 1985, to check whether their shrouds terminate INSIDE the mast. If so, you should have the terminal points undergo specialized inspection by whatever means your professional maintance provider offers. If at all possible, replacing the shrouds with EXTERNAL tang fittings would be an extremely prudent action.In my lucky case, no one was injured, the mast has been replaced (with EXTERNAL tangs)and the good vessel is as good...no BETTER, than ever!