sailboat mast refinishing

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• Boat Maintenance

Making an Anodized Mast Look Like New

Options for renewing your spar range from cleaning and painting to re-anodizing..

Have you done any research on the best means of cleaning an aluminum mast? Im having other work done to mine and thought it would be a good time for a cleaning.

Bob Pendleton

If your mast just needs a good cleaning and polish, then a non-abrasive cleaner/wax will work fine.

Our most comprehensive report on cleaner-polishes was Metal Cleaners (PS June 2006 online), in which we tested 16 different products. Wed opt for one of the liquid cleaner-waxes like Collinite No. 850 Metal Wax, a non-abrasive cleaner-wax is in the same family as Collinite No. 885 Marine. Other products that matched the Collinites performance in restoring and protecting metal were Meguiars Mirror Glaze Professional All Metal Polish, Mothers California Gold Chrome Polish, and Star brites Chrome and Stainless Polish. Star brite also makes Ultimate Aluminum Polish, which we have not yet tested.

There are more than a dozen such products on the market, but we can’t speak to their effectiveness. Avoid using a power tool for this job, and steer clear of abrasive cleaner/polishes. The anodized surface is very durable, but over-aggressive polishing will shorten its life.

If your mast is extremely weathered, you might consider coating it. While coating aluminum is tricky, its not too difficult for a confident do-it-yourselfer-or a classic car enthusiast who has restored a few old MGs.

There are two approaches here. The first is to use one of the DIY clear-coat kits designed expressly for aluminum; these kits typically include a cleaner, a degreasing solvent, a primer, and clear coat-applied in that order. The second option is to use a high-quality linear polyurethane (LPU) paint.

We have not tested any of the clear-coat kits. However, based on our experience with similar products, clear coating would be a two- to three-year solution, where as an LPU job can last 10 years or more. For both of these projects, the bulk of the labor is in the meticulous prep work required, so the longer-lasting LPU makes more sense to us.

Prepping the mast for LPU is a big project. For a proper job, youll want to remove as much hardware as possible. Then you need to wash, degrease, and prime (typically with a zinc-chromate primer) the surface before painting. Applying an LPU is not much different than painting a hull.

The Inside Practical Sailor blog post online Painting Your Boat Like a Pro (posted Oct. 5, 2016) has links to our LPU paint tests and related how-to articles. Marine-maintenance guru Don Caseys This Old Boat covers the basics of LPU painting as well and is available in PSs online bookstore.

It is important to remember that when you re-install any mast hardware, the hardware and screws or rivets must be isolated from the painted aluminum. For bedding, use a UV-resistant polyurethane sealant; for rivets (monel is preferred) or screws, most riggers use Tefgel, Tuffgel, or Duralac. If you skip this step, the paint will fail at the hardware interfaces within a couple of years.

If you have the funds to hand the project to a pro, you could have the mast re-anodized. Unpainted masts are protected from corrosion through anodizing, an electrochemical process that converts the metal into a shiny, anodic oxide finish.

Most cities will have an anodizing facility, but anodizing requires that the mast be immersed in an acid-electrolyte bath, and not all of them will have a tank to fit a mast. Charleston Spars, in Charleston, S.C., has a large facility that specializes in masts, and there are others around the country that also do this work-but youll definitely want to get references.

Powder-coating the mast (often with anodizing) is an option, and you can find powder-coating services in almost any big U.S. city. The facility you choose should have plenty of experience in powder-coating surfaces for the marine environment; Charleston Spars also does this work.

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Painting an Old Aluminum Mast

• Thread starter Tim Cross
• Start date Mar 17, 2004
• Forums for All Owners
• Ask All Sailors

*!Looking for experience and/or advice on best way to paint a 34 year old aluminum mast while out of the boat and on horses. Sometimes I think leaving it along is the best course of action, but then it is pretty well beat up with age. Tim  

awlgrip a fellow in the same marina as me painted his mast with "Awlgrip" he used a brush and tipped it out with a foam brush. It came out wonderful.  

Fred Ficarra

Awl-grip for me too I used those dense small roller brushes from Home Depot. They can be bought by the dozen and are solid looking but in fact are open cell foam. They hold a lot of paint even though they are only one inch in diameter. Apply paint for about 4-5 feet and then start over, tipping to where you stopped painting, with the SAME ROLLER, then load up and go again. Can't tell it from a spray gun. Problem! After I finished my standing rigging, it was time to do my hatches. The price of Awl grip went up (same summer) to the point that the small amount of paint I needed to coat my hatches cost nearly as much as POWDER COATING by a professional shop, all labor included. My hatches are powder coated. Good luck. Don't forget to ask for Awl grips' local rep who can give tips to you. It is very advisable that you have experience with sophisticated coatings. You can see how the mast came out, on my web site. It was pretty dull but not too corroded prior to the work.  

Can we expand this thread just a bit... I'm guessing Tim is asking about a typical spar which is past its prime. In most cases this means the extrusion was first irridited, then anodized (the silver or sometimes Euro gold finish) before being finished out. Subsequently, stainless fastenings have done their corrosive work (which spar mfgr, even today, properly beds stainless fastenings...?) on top of which there's a few abrasions here and there exposing raw aluminum.So...in the end, Tim's looking at painting untreated bare and slightly corroded aluminum, irridited/anodized surface, and more significantly corroded aluminum - all at once, of course. I've seen beautiful repainted spars where something as simple as Brightside paint was used (one-part polyurethane; inexpensive and easy to work with) but I'm wondering if anyone can speak from long-term experience about:1. Whether a metal etching primer (prior to the paint mfgr's recommended primer) made a difference relative to not using one when covering the mixed surfaces on a spar?2. Whether a paint mfgr's recommended paint primer (in the absence of a metal etch)effectively handled bare aluminum and corroded aluminum surfaces, long term?I repainted my Bomar aluminum hatch trim some years ago, using the full etch/prime/paint recommended sequence from International and it worked well. Moreover, now that they need a fresh coat, I feel confident of applying paint over paint subsequent to a good clean up, as the underlying bond is solid. But my hatches had no significant corrosion and I did use an etch. But with the need to repaint my spars in the future, I'm wondering if the full etch, then prime, then paint scheme typically recommended is in fact necessary. Any thoughts based on long-term results are surely recommended!Jack  

Painting an old alum. mast We repainted our alum. mast but used a different approach as suggested by a rigger. He suggested we wet sand the mast, wash it off, treat it with alum. prepainting solution and paint it with Krylon clear enamel. He suggested the clear enamel because it is a faster application because none of the fittings need to be masked off. It took us less than a day to complete the job with three coats of paint. Total cost about $40.Jay Tracy  

More details please Jay What grit sandpaper and what was the alum prep solution you used?How has it held up to weather, halyards, etc?Tim R  

One thing,,,, Any coating is only as good as the prep work. No matter what you put on for a finish, it's got to be over a good base. You have got to know what you are doing. A good paint job is 90% prep work. And old masts, 99%.  

Can you shine it? In order to clean my aluminum wheels on my Jeep, I recently obtained some acid based cleaner from NAPA. Worked like a charm, the wheels now really shine, and with no elbow grease. Why not really shine your aluminum mast? Leave it bare? Is it that beat-up?  

John Shullo

Name please Jesse:What is the name of the product you used to clean your wheels? I would love to try it on my mast and boom.John  

NAPA I believe it's called NAPA Aluminum Shine. It's acid based, so be careful.  

Appliance Enamal Gentlemen,Around here we go to Wal Mart and get 10 cans of the Appliance Epoxy Enamal.Works great.Great finish.Color selection a bit thin - but great cover.Paint onRD  

Correction Correction, that's NAPA Aluminum Brightener. If you use it let me know how it worked.  

Richard Lanier

How best to remove corroded fittings? This is a timely discussion. In a couple of weeks, I will be pulling the mast on a 1982 Hunter 30. The stainless steel fittings are well corroded. Anyone have recommendations for removing the fittings, cleaning the old corroded material, and preping the mast for painting?  

The Napa Aluminum Cleaner works After reading an earlier response from Jesse about the Napa product, I thought I would give it a try on my 1977 Cal 2-27. I applied it to the boom first with a paper towel and then a metal brush. The Napa Aluminum Brightner removed everything but the pits. The metal brush got most of them and a little light sanding and a final coat of the brightner made it new again. Note: do not apply wax after cleaning as it will streak and ruin the appearance. One more coat of brightner to remove the wax and it looks like new. EZ and cheap. Product was $6.95. Product is only for uncoated aluminum. Good luck.John  

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• Navigating the High Seas: A Comprehensive Guide to Sailboat Masts

Sailboat masts are the unsung heroes of the sailing world, silently supporting the sails and ensuring a smooth journey across the open waters. Whether you're a seasoned sailor or a novice, understanding the intricacies of sailboat masts is essential for a safe and enjoyable voyage. In this comprehensive guide, we will delve into the world of sailboat masts, discussing their types, maintenance, and everything in between. 

Types of Sailboat Masts

Sailboat masts come in various configurations, each with its advantages and drawbacks. The two primary types are keel-stepped and deck-stepped masts.

Keel-Stepped Masts

Keel-stepped masts are the most common type, extending through the deck and resting on the boat's keel. They provide excellent stability and are suitable for larger sailboats. However, they require careful maintenance to prevent water intrusion into the boat's cabin.

Deck-Stepped Masts

Deck-stepped masts rest on the deck of the boat, making them easier to install and remove. They are commonly found on smaller sailboats and are more forgiving in terms of maintenance. However, they may offer slightly less stability than keel-stepped masts.

Components of a Sailboat Mast

To understand mast maintenance better, it's essential to know the various components of a sailboat mast. The key parts include the masthead, spreaders, shrouds, and halyard sheaves.

The masthead is the topmost section of the mast, where the halyards are attached to raise and lower the sails. It also often houses instruments such as wind indicators and lights.

Spreaders and Shrouds

Spreaders are horizontal supports attached to the mast to help maintain the proper angle of the shrouds (cables or rods that provide lateral support to the mast). Properly adjusted spreaders and shrouds are crucial for mast stability and sail performance.

Mast Materials: Choosing the Right One

Sailboat masts are typically constructed from three primary materials: aluminum, wood, and carbon fiber. Each material has its unique characteristics and is suited to different sailing preferences.

Aluminum Masts

Aluminum masts are lightweight, durable, and relatively easy to maintain. They are commonly used in modern sailboats due to their cost-effectiveness and longevity.

Wooden Masts

Wooden masts, while classic and beautiful, require more maintenance than other materials. They are best suited for traditional or vintage sailboats, where aesthetics outweigh convenience.

Carbon Fiber Masts

Carbon fiber masts are the pinnacle of mast technology. They are incredibly lightweight and strong, enhancing a sailboat's performance. However, they come at a premium price.

Mast Maintenance

Proper mast maintenance is essential for safety and longevity. Regular cleaning, inspection, and addressing minor issues promptly can prevent costly repairs down the line.

Cleaning and Inspection

Regularly clean your mast to remove salt, dirt, and grime. Inspect it for signs of corrosion, wear, or damage, paying close attention to the masthead, spreaders, and shrouds.

Common Repairs and Their Costs

Common mast repairs include fixing corroded areas, replacing damaged spreaders, or repairing shrouds. The cost of repairs can vary widely, depending on the extent of the damage and the materials used.

Extending the Lifespan of Your Mast

Taking steps to prevent damage is essential. Avoid over-tightening halyards, protect your mast from UV radiation, and keep an eye on corrosion-prone areas.

Read our top notch articles on topics such as sailing, sailing tips and destinations in our Magazine .

Check out our latest sailing content:

Stepping and unstepping a mast.

Stepping and unstepping a mast is a crucial skill for any sailboat owner. This process involves removing or installing the mast on your boat. Here's a step-by-step guide for safe mast handling.

Step-by-Step Guide for Safe Mast Handling

• Gather the necessary tools and equipment.
• Disconnect all electrical and rigging connections.
• Use a crane or mast-stepping system to safely lower or raise the mast.
• Secure the mast in its proper place.
• Reconnect all electrical and rigging connections.

When and Why to Unstep a Mast

You may need to unstep your mast for various reasons, such as transporting your sailboat or performing extensive maintenance. It's crucial to follow the manufacturer's recommendations and ensure a safe unstepping process.

Sailboat Mast Boot: Protecting Your Mast

A mast boot is a simple yet effective way to protect your mast from water intrusion and damage caused by the elements. Here's what you need to know.

The Purpose of a Mast Boot

A mast boot is a flexible material that wraps around the mast at the deck level. It prevents water from entering the cabin through the mast opening, keeping your boat dry and comfortable.

Installing and Maintaining a Mast Boot

Installing a mast boot is a straightforward DIY task. Regularly inspect and replace it if you notice any signs of wear or damage.

Replacing a Sailboat Mast

Despite your best efforts in maintenance, there may come a time when you need to replace your sailboat mast. Here's what you should consider.

Signs That Your Mast Needs Replacement

Common signs include severe corrosion, structural damage, or fatigue cracks. If your mast is beyond repair, it's essential to invest in a replacement promptly.

The Cost of Mast Replacement

The cost of mast replacement can vary significantly depending on the type of mast, materials, and additional rigging needed. It's advisable to obtain multiple quotes from reputable marine professionals.

Yacht Masts: Sailing in Style

For those looking to take their sailing experience to the next level, upgrading to a yacht mast can be a game-changer.

Differences Between Sailboat and Yacht Masts

Yacht masts are typically taller and offer enhanced sail performance. They are often equipped with advanced rigging systems and technology for a more luxurious sailing experience.

Upgrading to a Yacht Mast

Consult with a marine professional to determine if upgrading to a yacht mast is feasible for your sailboat. It can be a significant investment but can transform your sailing adventures.

Sailboat Mast Steps: Climbing to the Top

Mast steps are handy additions to your mast, allowing easier access to perform maintenance or enjoy panoramic views. Here's how to use them safely.

Using Mast Steps Safely

Always use proper safety equipment when climbing mast steps. Make sure they are securely attached to the mast and regularly inspect them for wear or damage.

The Advantages of Mast Steps

Mast steps provide convenience and accessibility, making sailboat maintenance tasks more manageable. They also offer an elevated vantage point for breathtaking views while at anchor.

Mast Maintenance Tips for Beginners

If you're new to sailboat ownership, these mast maintenance tips will help you get started on the right foot.

Essential Care for First-Time Sailboat Owners

• Establish a regular maintenance schedule.
• Seek advice from experienced sailors.
• Invest in quality cleaning and maintenance products.

Preventing Common Mistakes

Avoid common pitfalls, such as neglecting inspections or using harsh cleaning agents that can damage your mast's finish.

Sailing with a Mast in Top Condition

A well-maintained mast contributes to a safer and more enjoyable sailing experience. It enhances your boat's performance and ensures you can rely on it in various weather conditions.

How a Well-Maintained Mast Improves Performance

A properly maintained mast helps maintain sail shape, reducing drag and improving speed. It also ensures that your rigging remains strong and secure.

Safety Considerations

Never compromise on safety. Regularly inspect your mast, rigging, and all associated components to prevent accidents while at sea.

Sailboat masts are the backbone of any sailing adventure, and understanding their intricacies is crucial for a successful voyage. From choosing the right mast material to proper maintenance and upgrading options, this guide has covered it all. By following these guidelines, you can sail the high seas with confidence, knowing that your mast is in top condition.

So what are you waiting for? Take a look at our range of charter boats and head to some of our favourite  sailing destinations.

I am ready to help you with booking a boat for your dream vacation. Contact me.

Denisa Kliner Nguyenová

Open for Retail and OEM/Rigger Sales! Check out the updated Dwyer Mast catalog and order online today.

Aluminum Sailboat Mast & Boom Extrusion

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Aluminium mast damage/repair

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Looking for some input and advise on damage done to a keel stepped aluminum mast. The boat was damaged in the tsunami last year and in the hast of getting her rigging removed and the boat hauled out of the water the owner did a number on the mast by using a sawzall to cut the mast free from the seal where the mast passed through the cabin top. There are gouges in the mast from the saw blade all they way around the mast. Most are fairly superficial but a few of the gouges cut about half way through the aluminum. I don't know much about aluminum and it's integrity. I am wondering what kind of repair could/should be done. How concerned should I be about structural issue of the mast as is? Unfortunately the yard where it is currently sitting does not have much knowledge in this area. Any recommendation on repair facilities in the Pacific Northwest would also be appreciated? Attached are the pictures of the gouging. https://picasaweb.google.com/116769935838961759366/June22012 Thanks you for any advise or input.  

I'm not a metallurgist. Most of the damage I see in your pics looks superficial. The mast has to stand up to compression loads. I'm not sure if you should have the newly exposed aluminum anodized but likely a good idea. I'd also guess that with some marine epoxy and cloth you could build up a collar over the damaged area. What kind of boat is it? Welcome to sailnut.  

Don't cover it up with epoxy, that will allow moisture to do even more damage over time. You should have the mast sleeved for a best result. Wow, a sawsall, people never cease to amaze me with the things they do.  

Sleeve it or replace it are the only two options. Any gouges that go deep into the metal at a minimum will create major stress risers, and will cause the mast to fail when it's stressed.  

Do nothing radical, Here's what I'd do. Wrap it in wax paper tightly. Split a large piece of PVC pipe to go around it over the wax paper with maybe 3/8" clearance. At bottom of PVC, cover the gap with duct tape. Fill the annular space with epoxy and allow to set. Carefully use a hacksaw to slit the epoxy inside where the PVC is slit. The wax paper is your release layer. You now have a mold of your mast in two halves. Use huge SS hose clamps to hold it around your mast. You can remove it whenever you like for inspection but I'd seal the top around the mast with silicone seal.  

While your at it pray to fairys to keep your mast up. About as effective.  

PNW... Call CSR in Seattle.  

I'd probably get section of mast and sleeve it. That's a bad place to screw around with a cosmetic fix.  

CableB - The boat is a Tashiba 31. Beautiful boat in great shape other then the hack job on the mast. Puddinlegs - Thanks for the reference, I'll look em up.  

You now have a mold of your mast in two halves. Use huge SS hose clamps to hold it around your mast. Click to expand...

What I have seen done is to get maybe a 3' section of the exact mast extrusion (unless it's a real oddball, they are somewhat standard and available), slice it along its length so that it can be squeezed to slide up inside the existing mast. Smear with epoxy, slide one inside the other and s.s. rivet them together. This can even be done to join two broken pieces of a mast. The outside can then be faired out to look better.  

Smurphey, This is the basic process of sleaving, except that you use a extrusion piece made specifically to match the mast you have. These pieces are available from most manufacturers even for mast profiles that are no longer made (they keep the dies for this purpose). Cutting a section of a mast down the middle though has two problems. 1) it probably won't fit, since most masts have a different inside profile than outside, and 2) significantly weakens the sleeve. Remember particularly since this repair is at the bottom, it has to handle all the compression loads and torque loads generated in the entire mast. Weakened sections here are a major problem.  

Certainly even better to have a piece that will fit exactly. The older simple oval mast shapes work pretty well shrinking them by slitting on one end of the egg shape but having a complete section would be much better. In a keel stepped mast like this one, there can be a lot of movement and stress at the deck intersection so whatever the OP does, it needs to be more than cosmetic. Am wondering if a good welder could not build up the hacked areas and grind down smooth or just fish plate it. Would have to be someone experienced at welding aluminum masts.  

Thanks you all for your input. We had a guy from an aluminium fabrication shop take a look at it today. He said he could weld it up no problem but wouldn't put any guarantee on the integrity of the mast, even though he thought that would be a sufficient repair. For the sleeve fix, that seems beyond what I would want to try as a DIY project which means I would have to ship the mast to a yard that could do the work. For reason mentioned in early posts I am concerned with the location of the scratches/gouges so am not sure I could sleep easy wondering if the weld really is enough of a fix. Decisions decisions......  

It could not hurt to have a sleeve right at that point where it gets wedged. The only thing I'd worry about with welding on plates is what the heat and differential in flex caused by dissimilar materials might do to the long-term strength, especially around a circumference. Can you get an exact fit interior sleeve? If so, that would seem like the way to go.  

If you really can't afford a new mast - make a compression post from the base of the mast step to the underside of the deck with enough fiberglass and metal to act as a mast step/collar and deck step the mast. Might have to add a few deck stringers to support the weight.  

Lanya, Call the extrusion maker and talk to them. Sleaves can be welded in place, but can also be riveted in place. Particularly where as here, there is some remaining strength in the extrusion you have.  

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