How to Avoid Costly Sailboat Mast Repairs

Your sailboat mast has to carry the weight of sails and sailing rigging in all wind conditions. Follow these five tips to find hidden mast weaknesses before they end up costing you big $$$'s in repair or replacement costs!

1. Use Your Eyes for the Straight Truth

Make this test with a mast still on the boat. Site up the mast on all sides. It should be straight without bowing out to one side or the other. It should not have any forward bend (called rake) either. It's o.k. to have some aft bend as long as it isn't excessive. If the mast appears straight, check the upper shrouds with this test:

a. Ease the mainsail halyard. Pull the halyard the shackle over to one of the upper shroud turnbuckles and hold it there.
b. Take the slack out of the halyard and cleat it off.
c. Move to the upper shroud turnbuckle on the opposite side side. It should touch at the same point as before.

If it doesn't, the mast will not stay straight under sail. Before you test sail the boat, ask the owner if you can adjust the upper shrouds so that they are even. You will need to do this so that the boat sails to her best on both tacks.

2. Locate Secret Signs of Mast Weakness

The bottom of the mast, or heel, sits in a step on the deck or near the keel. Deck steps look like large oval shaped coasters. You should see a drain hole on one side (this allows water to drain). Corrosion or cracks near the heel tell you that water inside the step didn't drain.

Keel stepped masts penetrate the deck and mount onto a step on a shelf near the keel. Check for corrrosion in two areas. Lift up the mast boot (a rubberized collar that fills the deck hole) to check for corrosion underneath. Then, check the heel in the step near the keel for corrosion and cracking.

In either case, you may be looking at internal corrosion that has penetrated and weakened the mast at the heel. This could require expensive surgery or a full mast replacement. Walk away from any boat with this problem.

3. Beware of Excessive Dings and Dongs

Scratches, scarring and dents means that halyards with metal shackles have taped and rattled onto the mast. This removed the delicate coating that protects the mast from corrosion. And it also tells you the care the owner has taken. Unless you see severe dimples in the spar, you can clean and wax scratches to protect them in the future. Make a careful note where these are for future reference.

4. Look for Dishing that Means Squishing

Bend down near the coach roof and sight along the area of the mast step. If the deck has a concave shape in that area, the mast support under the step has failed. This will require extensive and costly repair to rip out the old support structure and replace it.

5. Check for Elongated or Corroded Mast Fittings

Mast fittings are best checked with the mast off the boat, unless you want to take a trip to the masthead. Start your inspection at the heel and work up to the cap at the top of the mast. Check for corrosion where any fitting joins to the mast.

The spreaders should be straight without bends or cracks. Spreader angles should be the same on both sides. Pull the shrouds to check for spreader base separation.

Check the tangs where the lower and upper shrouds and stays attach. The holes should not show any sign of cracking or elongation (oval shape). Block sheaves should turn easily without wobbling inside the cheeks.

Make the sailboat mast a hot priority on your inspection list when looking for that perfect small cruising sailboat. Use these five tips and you will find a strong, well maintained mast without the worry of unexpected, expensive replacement costs.

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Captain John is the author of the new blockbuster skipper's guide from International Marine: Seamanship Secrets, 185 Tips and Techniques for Better Navigation, Cruise Planning, and Boat Handling Under Power or Sail.

Learn the fastest, easiest ways to become a top-notch cruising boat skipper! Order your copy today from Amazon, Barnes & Noble, or Borders bookstores. ========================================================================