Mast step replacement - bolts

[Randy]

Need some advise from those who have gone before me. I am going to replace my rusted out mast step. I know I can order a replacement from Rig-Rite? My question concerns the bolts that secure the step to the keel. Mine are really rusted with not much of the bolt head left. Are the originals lag type bolts with wood threads or machine type bolts? If I cannot get them out of the keel, what do you suggest? Drill new holes and secure with new bolts in a new location on the step? If that is the case, what type of bolts would you use and how best to secure them in the keel?

Cheers,
Randy

[INCOMMUNICADO]

Randy,  this may give you a different way of looking at your step replacement.  With the mast removed and a 4" grinder in hand, remove what was left of the bolt heads.  Then comes time for the hammer and pry bar.  With that rusty mess gone, back to the grinder to flush bolts to surface of bilge.  Next, I sanded and cleaned the area for the new step.

The new step is made from two 2x10's, face epoxied and clamped together, then cut to size.  Next they get glassed into the bilge.  Next a tempered aluminum 1/4" plate with a 1 1/4" mast retention ring.  The plate was bolted to the base 4 3/8" galvanized lag bolts.  I will have to go to the boat for the finished dimensions.

I cut 3 1/4" off the mast.  My new step is 3 1/4" high.  Now the mast never sits in water. 

I did this project more than 10 years ago and it still looks the same.  I don't think the step will ever be a problem.

The project was probably less than $50.00 because I pulled the mast for other projects.  Hope this helps, Allen

[PeteW]

Getting the lag bolts out with vice-grips is what you will need to do. Its a coarse thread so it should not take much to loosen them. I don't think leaving them is an option. It will only complicate the entire job.  They are screwed in the lead ballast which is a very soft metal but there might be some epoxy down the hole.

There's several threads on mast step replacement:

Dale machined his step from aluminum. My design is nearly identical but built from
phenolic.

http://www.pearson365.com/forum/index.php?topic=1259.msg6787#msg6787

http://www.pearson365.com/forum/index.php?topic=113.15

I replaced my step with the boat in the slip. No need to pull the stick.  If you want a mast collar to jack up the mast I'll put it in  the chandlery cheap. SOP amongst shipwrights.

Pete

[Randy]

Thanks Pete & Allen. I am going to pull the mast (as i want to replace VHF ant, masthead light, running and spreader lights) and I will remove mast step and take it one step at a time. I am sure I will be calling on you again soon.

Thanks for the input.

Randy

[SVJourney]

Alan,

I am looking at doing a glass build up and aluminum plate.  What did you do for the tension rod thread?  From my experience, 1/4 in aluminum would not be enough meat to expect it to hold the threads on the rod.  Insert?

Wayne

[INCOMMUNICADO]

Wayne, Extend the threads on the rod another 3 to 4 inches thread the plate. If you think you need more weld a nut on the backside of the plate. Allen