I now have 2 bottom sections of 460 masts (ie. 4 pieces + tops, both masts broke in same place) and was wondering if anyone has tried to repair masts by 'shimming' them? I'm happy to sacrifice one to make a full (half).

Now the questions....

(a.) do I cut the older (possibly more brittle, but thinner/lighter) 90% mast to make a shim for the newer (3yo) 30% mast, or vice-versa?

(2.) what bonding adhesive should I use, a polyurethane (flexible) sika-type, or araldite/fibreglass.

(III.) is this worth even attempting???

(d.) does anyone have a lonely 460 mast bottom piece to save me the embarassment of another swim when this (repaired) one breaks?!? (although I'm that stingy, I'll probably still try to repair it, just to have a spare)

All advice will be taken onboard, but possibly ignored in the name of science and stupidity (on my part)!

Mark _australia said...


It would need to be an epoxy resin or similar

However, I think it would not be worth the effort: fibres are continuous along the length of the mast, so joining 2 sections is not as strong as the original. Thus, to make it strong enough you have to put in so much extra material that the bend curve would be totally stuffed.
To join some top sections to make a mast to rig a 2.5m learners/kids sail from 1990, yes.
For adult use with any modern sail, no.

I have never had much success joining parts of broken masts it is definitely worth a try. Try to get the sleeve to fit as closely as possible. What Mark says about continuous fibers along the length of the mast is true, BUT, remember that all masts today are two piece and they seldom break at the join so it must be possible. Of course, a great deal of thought and manufacturing precision goes into those factory joints!

in the fiberglass mast days we often repaired broken masts.

We never cut them off flush though, I think if you put both ends back together with the rough join you will more likely have a greater success rather than having the clean join.

For the old repairs I only ever had to do top sections and didn't sleeve it, just set it all up and wrapped 2in wide matting around the crack for about 300mm either side.

Had some success with this, however I am not sure I would waste my time these days given the extra forces put on modern masts and the technology involved in their construction.

Just use them to hang a wind sock in you back yard, always useful for getting a footy out of a tree as well.

aus301 said...

Just use them to hang a wind sock in you back yard, always useful for getting a footy out of a tree as well.

I think if you put both ends back together with the rough join you will more likely have a greater success

Ummm...already got one in the back yard, on an aluminium mast......got an old fibreglass mast in the shed, and 2 17ft lengths of bamboo (with flags, used when crossing the sand dunes to alert dune buggys). As for not cutting, they both splintered out....the carbon shatters, got a nice little splinter in my hand!