Jim Woodward wrote:

I think we've missed something here, Doug. The drawing at
http://www.pearsonvanguard.homestead...les/index2.htm
isn't very clear, but I think the mast is stepped on deck.

I get a broken link. Can't see a thing. IIRC almost all the Phil Rhodes designs
had keel stepped masts, but my memory ain't what I used to think it was.



The door to the
head appears to be on center directly below the mast, so the step carries
the load to posts at the fore and aft head bulkheads.

Aye caramba... could that be the way it's 'sposed to be? Not even a cross beam
under the cabin top skin? It's hard for me to believe Rhodes designed it this
way!



Also, the drawing of the suggested step at
http://www.pearsonvanguard.homestead...les/index2.htm
doesn't specify a material, but it calls out 5/16" plate. That's pretty
beefy in steel, so I suspect aluminum was in mind.

I agree that for a step out of sight in the bilge, that modern glass and
epoxy would be at least as good as, maybe better than aluminum, and,
something that a reasonably competent DIY person could do.

For one that's in sight on deck, however, aluminum is likely to be prettier
unless the builder does a lot of work on finishing, hard to do inside a
complicated piece.

Or use peel ply. Still have to do some sanding & finishing, but not as much as
with steel. Here's where aluminum has a big advantage... no finishing, and it's
sure to be a bit lighter than the FG piece. If it's going to be outside in the
weather, I'd doubly rather have a chunk of fiberglass, plus you can put nice
rounded corners on it.



Another possibility would be to use commercial fiberglass shapes -- either
channel or angles -- plenty of strength, easy to fab in the home shop, and
would look very professional when painted. (go to www.mcmaster.com and
search on fiberglass channel or angle -- McMaster is not a low cost or
specialist vendor, but they have some of everything you can imagine).

Good idea.

I can tell you firsthand that molding small custom fiberglass structural pieces
doesn't take a lot of skill or money, but it does take some time. Looks like
McMasters could save a goodly numbert of hours.

Fresh Breezes- Doug King