Mast Beam Final

In the last week of 2009, I continued work on the mast beams. It was time to bed the beams in thickened epoxy (West System, w/ 407 and 406). After creating a template of the overhead and cutting out the beams, with a number of subsequent cuts here and there as well as a whole lot of sanding, I planned to bed the beams in epoxy to create a very snug fit against the overhead.

First step was to prepare the overhead for a good bond with the epoxy. I sanded the old primer / paint to expose the fiberglass along the length of the original mast support beams. I then finished up with an acetone wipe down.

Next, I taped my newly formed mast beams to protect against the epoxy application. Here are the two beams as they were prepared to be bedded in the thickened epoxy mixture.

I didn’t take pictures of the beams as they were bedded in the epoxy, but all came out satisfactory. After the epoxy had cured, I removed the beams, washed the amine blush from the surface of the epoxy and then sanded to accept primer - eventually. I finished the day by removing the tape from the beams, and giving them a once over sanding with 100 grit paper. The tape removal was not an easy task, but was completed nevertheless.

I took the beams home and prepared them for a coating of teak oil.

I did not plan on varnishing the oak beams, but instead wanted to dress the wood with a protective layer of oil. Here are the before and after shots.

I ordered some 316 stainless bolts, washers, and locking nylon nuts.

These will secure the new beams to the existing original mast support.