What materials to use for mast step repair?

[Project_Mayhem]

What wood or composite material would you use to replace the rotted wood in a mast step? I've heard anything from balsa, hardwood, plywood to an aluminum block.

How many layers and what type of glass would you lay down and in what order? I've done this repair before but I'm interested in a better method of repair

 

[Spindrift NH]

Catalina sells a white oak replacement mast step. You might try the SBO store first.
I replaced the one on my ‘88 with an aluminum screw jack that I had made.

 

[Project_Mayhem]

Catalina sells a white oak replacement mast step. You might try the SBO store first.
I replaced the one on my ‘88 with an aluminum screw jack that I had made.

Thanks for the tip. Is there different grades of white oak? I found this for $11. At that price it's not worth it to hunt down one from Catalina.

That screw jack looks much taller than the wood I would expect to find inside a mast step. I assume that is for a keel stepped mast?

 

[FastOlson]

The answer is G10/FR4 composite. Repeat until memorized. You can usually buy it cut to the general dimensions you need. And/or have a saw on hand with bi-metallic blades.
Also, since thicker versions cost disproportionately more, use thickened epoxy to bind together several layers of 1/4 or 3/8 to reach the thickness needed. McMaster Carr has it, or find a local plastics supplier. While hardwood can suffice, it's really difficult to treat it deep moisture (and rot) out of it over time.

 

[Project_Mayhem]

The answer is G10/FR4 composite. Repeat until memorized. You can usually buy it cut to the general dimensions you need. And/or have a saw on hand with bi-metallic blades.
Also, since thicker versions cost disproportionately more, use thickened epoxy to bind together several layers of 1/4 or 3/8 to reach the thickness needed. McMaster Carr has it, or find a local plastics supplier. While hardwood can suffice, it's really difficult to treat it deep moisture (and rot) out of it over time.

I have a small scrap of G10 and it is tough stuff! I assume using all epoxy and mat/cloth and no wood would be too brittle?

 

[David in Sandusky]

I used an aluminum plate for mine. The work was done by a fiberglass shop in Cleveland. Total satisfaction with no issues for 24 years now.