Thanks for all the input. Sounds like an artfull welder with maximum
emphasis on cool welding, and then maybe inject the bottom 2 ft with closed
cell foam or something to spread the load. I'll keep a good eye on the
repair, looking for stress cracks, as we shakedown on the way to the east
coast from Lake Ontario. If it shows any stress, I'll cut the mast off at
the bottom and raise the mast base up 10 in..Lowering the rigging would be a
job and a half.
Thanks again.
Dave
www.blueeden.ca
Nice cutter Glenn.

"Tadeusz Jerzy Korsak" wrote in message
...

U¿ytkownik "Dave Buttle" napisa³ w wiadomo¶ci
...
Someone cut a nasty hole at the bottom of the mast (with square
corners).
I have attached photos of the mast needing repair. Two of the lower
corners
of the square hole have started to crack slightly. The hole is not
needed,
so it could be closed up. The mast is 72' tall, stepped on deck. I would
be
grateful if anyone could advise me of how, and with which material, this
repair could be welded up for maximum strength. The concern is that this
is
an offshore boat. We are preparing for an North Atlantic
circumnavigation.
More on our trip preparations. www.blueeden.ca
Dave

If the square hole is located at very bottom of the mast, near the mast
step, I would consider filling the mast interior completely with composite
mixture (e.g. epoxy mixed with portland cement).
Square hole must be patched beforehand with proper composite prepreg patch
and composite filling apparatus must be constructed (e.g. basing on the
grease gun mechanism). Mast bottom section must be sealed also. Operation
should be performed on mast in vertical position and amount of mixture
calculated to provide filling to the proper level.
This filling will spread vertical forces from the mast on a much bigger
area.
Regards
Tadeusz