27 Photos - Jul 13, 2014
Photo: Pilgrim's mast collar.  Added along with new mast in 2002.Photo: I am unsure what sealant was used to bed the mast collar. Fortuntely it peeled away from the deck easily.Photo: water damage to what I assume is original plywood backing plate at the mast parteners.  Water intrusion from poorly sealed bolts on the mast collar caused the damage.Photo: mast parteners - note voids in deck lay-up on both sidesPhoto: using the original mast collar backing plate as a template for the new one.  Using 3/4" marine plywood for the new plate.Photo: rough cutting the new mast collar backing plate.Photo: using the drum sander to fine tune the inside radius of the new backing platePhoto: drilling pilot holes to test fit in PilgrimPhoto: Fitting the new mast collar backing plate to the original space took some fine tuning with the sander.  Test fitting also convinced me that the plate should extend below the headliner so that any future leaks will be promptly identified.  The best way to extend the backing plate is to add a second layer of 3/4" plywood.Photo: With a second layer of 3/4" plywood laminated to the first, I returned to the drum sander to fair out the edges of the now 1 1/2" thick backing platePhoto: dry fitting the new plate and marking the location of the bolts.Photo: dry fitting the new plate and marking the location of the bolts.Photo: using a dowel with 80 grit sand paper attached to sand out 1" holes at site of all fasteners.Photo: using duct tape to seal the bottom of the 1" holesPhoto: ready for filling the holes with thickend epoxyPhoto: epoxy thickened with micro fibers and west 404 curing in the 1" diameter holes.Photo: mast collar backing plate complete with 4 coats of epoxy on exteriorPhoto: cutting 1/2 plywood to fill the void at the mast partenersPhoto: covering new mast collar backing plate in duct tape to prevent epoxy used for filling the deck voids from adheringPhoto: after filling the deck voids with epoxy & plywood I clamped the new backing plate in postion to hold the repairs in placePhoto: Fearing the epoxy would kick too hot on the sunny 86F day I employed a combination of shade, ice, and fan to keep cool the deck while the epoxy set up.Photo: voids around the mast parteners filled with a combination of thickened epoxy and plywoodPhoto: New mast collar backing plate installed.Photo: New mast collar backing plate installed.Photo: Anne working on the topsides during the mast collat and backing plate installationPhoto: Using a screen roller to work a bead of butyl-tape sealant into channel on mast coller.Photo: mast collar re-installed with butyl-tape as bedding and new backing plate.