How should I weld this? Aluminum sailboat mast base.

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I purchased this sailboat a few years ago.The base that the sailboat's mast fits into is chipped.  I believe this is aluminum.The bolts are probably 304 or 316 stainless steel.  I am not sure what type of metal the square is, either steel or aluminum.  Inside the boat, I am also unsure of the painted metal: steel or aluminum.The rollie bits you see are sheaves (pulleys); they are bronze.How do I repair the chip in the base?What skill level is needed for this type of repair?  I am okay with stick welding.  I have done mig and tig, but I prefer stick.Is this something to have done at the boat or just take the base to the welding shop?An interior picture shows what the base bolts onto below the deck.As you can see there is some saltwater corrosion on the mast base.  The square panel which the base sits on is painted; the paint is flaking due to age.  The boat was built in 1981.The previous owner did not have the aluminum chip which broke out.  He said that he did not have any problems using it this way, but I would still like to get it fixed.Thank you for your thoughts and input.




Last edited by ericsarratt; 16 Hours Ago at 10:57 AM.
Reply:The mast goes over this "shoe"? (not inside...)
Reply:Well since I am a tig guy I would tig weld it with 4943 filler.  Wash the inside, and dress the outside. Reason I say this is that with tig you can boil out the contaminants as you go. It will be dirty but it is doable.Weld like a "WELDOR", not a wel-"DERR"

MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:If some asked me "what would you recommend as the best way to deal with this"?I would opt for removing the chipped casting and square plate assembly as a unit from the deck. Then there would be access to the fasteners between the chipped casting and the plate and they can be separated. Here I would grit blast that casting and build up the missing metal with TIG and also use 4943 filler.It can be finished out to be undetectable. From there I would recommend powder coating both parts and reassemble with new 316 stainless hardware and a suitable bedding compound between all the joints.Ernie F.
Reply:

Originally Posted by BaTu

The mast goes over this "shoe"? (not inside...)
Reply:I do not know if mast has heat treatment . If dose then when weld it will weak at the weld site.You find out if heat treaded before you can welding.  Some on this site would just welded not a good idea. Dave

Originally Posted by ericsarratt

I purchased this sailboat a few years ago.The base that the sailboat's mast fits into is chipped.  I believe this is aluminum.The bolts are probably 304 or 316 stainless steel.  I am not sure what type of metal the square is, either steel or aluminum.  Inside the boat, I am also unsure of the painted metal: steel or aluminum.The rollie bits you see are sheaves (pulleys); they are bronze.How do I repair the chip in the base?What skill level is needed for this type of repair?  I am okay with stick welding.  I have done mig and tig, but I prefer stick.Is this something to have done at the boat or just take the base to the welding shop?An interior picture shows what the base bolts onto below the deck.As you can see there is some saltwater corrosion on the mast base.  The square panel which the base sits on is painted; the paint is flaking due to age.  The boat was built in 1981.The previous owner did not have the aluminum chip which broke out.  He said that he did not have any problems using it this way, but I would still like to get it fixed.Thank you for your thoughts and input.





Reply:If is heat treated then to make new show that goes up in or out side the mast. Dave

Originally Posted by ericsarratt

I purchased this sailboat a few years ago.The base that the sailboat's mast fits into is chipped.  I believe this is aluminum.The bolts are probably 304 or 316 stainless steel.  I am not sure what type of metal the square is, either steel or aluminum.  Inside the boat, I am also unsure of the painted metal: steel or aluminum.The rollie bits you see are sheaves (pulleys); they are bronze.How do I repair the chip in the base?What skill level is needed for this type of repair?  I am okay with stick welding.  I have done mig and tig, but I prefer stick.Is this something to have done at the boat or just take the base to the welding shop?An interior picture shows what the base bolts onto below the deck.As you can see there is some saltwater corrosion on the mast base.  The square panel which the base sits on is painted; the paint is flaking due to age.  The boat was built in 1981.The previous owner did not have the aluminum chip which broke out.  He said that he did not have any problems using it this way, but I would still like to get it fixed.Thank you for your thoughts and input.





Reply:

Originally Posted by ericsarratt

I have never thought about it as I've never had the boat in the water.I stand corrected.  The mast slips over the shoe.  Here are pictures.
Reply:

Originally Posted by BaTu

I wouldn't worry about it then...The shear forces, the reduction on that shoe from the missing piece, wouldn't concern me. This probably happened a Long time ago, during the stepping process, and didn't concern the previous owner either


Reply:That looks like a job to send out to a boat builder and get a new one.Retired Old GuyHobart 210Lincoln AC/DC 225/125 Evolution 14” Saw
Reply:It's serviceable the way it is and the mast is literary stayed down to it by the rigging. The casting is hidden in service. I feel like the mast seized to it at some point and was broken away when the last was unstepped. The corrosion makes it a pain in the butt to do a nice job restoring it with weld - time consuming work for and experienced welder to build it up and shape it down. If a new or used casting is available that might be a better even possibly a cheaper option. If you do reinstall the mast use and anti corrosive grease on the step and bolts it can save some headaches.
Reply:Odds are they make a new shoe for mast to fit into. There is a lot of stress at bottom of mast. The stress is what broke the shoe in first place.  So looking at a manufacturer error. Where live there is lot of boat manufacturers they of some castings heat treated. There is tenzenalo ( spelling is not right) aluminum castings too. But this aluminum should not be welded it age type harding. Some will tig weld with rod made from the foundry out of tenzenalo (spelling is not right) . They do not make a wire for tenzenalo ( spelling is not right) Dave

Originally Posted by NotaVegetarian

That looks like a job to send out to a boat builder and get a new one.