Wooden insert at base of CF mast. BC23

[Jeremy Apted]

There is a wooden insert within the cylindrical carbon fibre mast which adds strength for when the pin is pushed through the base of the mast and held within the mast step.

The wood has deteriorated and needs replacing. I have read previous blogs which suggest using teak as it does not expand, such that it mitigates the risk of the CF mast splitting. There also appears to be some kind of epoxy barrier between the timber and inner surface of the mast.Please refer to attached photos.

Can anyone share there experience on how they have gone about making a new insert and how they have applied the epoxy barrier?

Merry Christmas.
Jeremy Apted
Whistling Kite
BC23

[Llafurio]

There is a wooden insert within the cylindrical carbon fibre mast which adds strength for when the pin is pushed through the base of the mast and held within the mast step. ...
Can anyone share there experience on how they have gone about making a new insert and how they have applied the epoxy barrier?

Get a suitable size piece of teak (or Bangkirai), get (someone with) a wood lathe, turn the wood piece down so it fits not overly tight inside the mast, and do not forget to leave a small wider shoulder (5mm length min.) at the lower end, about 3 mm wider than the outer mast diameter.

That "epoxy barrier" you mention appears to simply having been the "glue" they have used to keep the old rotten piece in place. Forget about the epoxy, it never holds there. Just use some perma flexible Sikaflex or similar marine sealant to fit the wooden plug in. I usually secure the plug with one or two s/s screws.

That piece of hardwood should be protruding at least 1x the inner diameter into the mast if it's a mastfoot plug (I always make them longer), and at least 2.5 times longer if it's a mast top plug where lateral forces come in also.

About that sealant: The buoyancy of the hollow mast is a critical factor for re-righting the boat from knockdown or inversion. While this may be less relevant for a BC 23, it is vital for all BR's. So I have always been careful to build my masts (and the c/f yards) as watertight as possible. I would recommend you do that too.

In any case, absolutely avoid using softwood or inferior unsuitable wood for the plug. My teakwood plugs are now in for up to 20 years, with none ever breaking or with signs of wear or rot.
C.

P.S.
I attach a photo of the mast foot plug I originally built from teakwood for the first SeaRaider in 2006. It was built square because the SR had a different tabernacle design than the later BRs. And it was built a little longer because the c/f mast tube was only 16 1/2 ft. in length. This mast and foot plug was later adapted and served on all my later boats in succession, until now being used on the Drascombe Drifter. Once built solid, it lasts for ages.