Hybrid Aluminum or Steel / Wood masts

  • 16 Jun 2025 01:06
    Reply # 13510614 on 13510080

    Got it. Thank you. Well that idea could make the project much more affordable as well then. 
    I just dug Practical Junk Rig out of my storage unit and will do some studying. 

  • 15 Jun 2025 22:22
    Reply # 13510581 on 13510080
    Anonymous member (Administrator)

    Straight. You can't buy tapered aluminium tube in New Zealand. The wood top extension is tapered.

  • 15 Jun 2025 22:15
    Reply # 13510579 on 13510080

    I'm looking at Annie's blog right now. It's hard to tell if the Aluminum tube is tapered ? Or completely straight??

    Last modified: 16 Jun 2025 15:17 | Anonymous member
  • 14 Jun 2025 14:50
    Reply # 13510306 on 13510080

    Hello Graeme!


    Thanks for the reply!  Annie’s blog was the first place I went to look! 
    Your explanation really helps, especially with my questions about the top mast twisting. 
    it appears that Simsons , which must be a New Zealand product? Is a form of polysulfide adhesive. Easily found here as  3M 5200. 

    Another possibility instead of a hybrid mast would be to build a tabernacle and get more length  that way. 

    Let’s see what unfolds. 

  • 14 Jun 2025 09:35
    Reply # 13510272 on 13510080
    Anonymous member (Administrator)

    I'm surprised someone hasn't chimed in already.

    I haven't made hybrid wood/aluminium but I have done a topmast extension with aluminium/aluminium and the principle should be the same.

    I don't think fastenings are desirable or necessary.

    There are three forces at play which need to be considered.

    (1) Bending. The standard rule of thumb is to bury 10% of the extension (same as the mast itself - the "10% above partners" rule). If the extension is 5' (say, 2m) then the "bury" or overlap needs to be 20cm minimum. This seems ridiculously small, so why not just make it arbitrarily, say, 30 or 40cm.

    (2) The downward force due to halyard and lifts - the weight of the rig. The obvious way is to have a shoulder at the join, which not only creates a smooth transition but also makes it impossible for the topmast extension to "telescope" into the mast.

    (3) The rotational force that the rig transmits to the mast. This is considerable, and is the only reason why you might want to put mechanical fastenings between the mast and the extension. However, the wooden topmast is presumably going to be made to fit nicely into the mast tube, and the faying surfaces will be quite great - glue should be sufficient to prevent the topmast twisting or rotating inside the mast tube. I have used epoxy glue, but I am advised that a different sort of adhesive would be better - especially when gluing two materials which have quite different characteristics. A polyurethane rubber, I believe, is a better proposition - there are various brands, for example "Simsons". The extension should fit into the mast tube with enough tolerance to allow a good body of this synthetic rubber glue.

    Can the wooden topmast be hollow? Why not?

    Also you could (and should) give it some taper.

    You won't find a better description than Annie's, in her blog here

    As an afterthought: you will note in Annie's blog, she refers to an issue of getting good alignment - the glue is soft, and you don't want to have a slight bend at the join - it might be visible. The two parts need to be colinear while the glue sets off. You want to decide how you are going to ensure this before you have applied the glue. 

    Last modified: 14 Jun 2025 10:02 | Anonymous member (Administrator)
  • 13 Jun 2025 19:07
    Message # 13510080

    Hello everyone,

    I am contemplating a conversion here in California , and as all Americans know , finding a suitable stick is not always easy ...or affordable.

    I have found a few galvanized steel light poles that seem to be the right dimensions , but are just 5-7 feet too short.

    I know Annie has spoken a bunch about Hybrid masts and my main question is how the 2 pieces are joined / fastened together? Is the wood "top mast " hollow for wires etc??


    Thanks


    Jonny

       " ...there is nothing - absolutely nothing - half so much worth doing as simply messing about in junk-rigged boats" 
                                                               - the Chinese Water Rat

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