I'm not sure you need to be quite so enthusiastic about keeping the mast in place.  It's not a very heavy thing and, really, all you want to do is to stop it shooting out of the step should you hit a 'square' wave, or inadvertently run aground at speed.  Or, I suppose, stop the mast from falling out should you capsize, which is a consideration if you intend adventurous sailing.

I hold my mast in place with a wee bottle screw between a two saddle eyes.  A big hole through the mast does weaken it at that point.

Jonny,

yesterday, as I helped stepping Johanna’s 10.6m x 25cm  wooden mast, I took this photo of the mast step, right after stepping.

As can be seen, the step consists of a pile of plywood bits, epoxied to the hull and to each other. I carefully grinded away the gelcoat from the hull to make the glue stick better.

Arne

Hi Jonny

I have made all my mast steps from plywood, and am about to start another one now. I have made the last two ones from two main pieces: First I build up a flat , wide “step sole” (width depending on hull shape) of 40-60mm plywood. I dryfit the plywood bits first and then glue them up in the hull, ensuring good bond to the hull and to each other. Then I laminate the “step collar” from plywood, 40 – 60mm thick, and with the mast hole right through it. This piece can be trial-fitted to the mast in advance of stepping the mast. This step collar I make a little smaller (in outer length and width) than the step sole. That lets me shift it around a bit on top of the step sole. When stepping the mast for the first time, I have just fastened the step collar with 2-3 screws. The temporarily stepped mast can then be checked for alignment. It may be necessary to reposition the step collar once or twice to get it right. When I am happy with it, I pull out the mast again to let me fasten the step collar permanently with epoxy and/or screws. Carving a  drain “furrow” in the underside of the step collar will prevent the mast from standing in a puddle in case of a leak at the mast gasket.

Arne

Next week! 

Jonny Kaplan wrote:

But …I have seen  other boats , large  than mine that have just used a wood / plywood / epoxy / sheathed in fiberglass for the step and partners.

My question is….does that seem strong enough??? It is most certainly more affordable

Any advice / ideas is GREATLY appreciated!

thanks

Jonny

Absolutely! Layers of thick plywood, bonded with epoxy, are an excellent way to make these. Just provide enough depth in the partners and step to spread the load over the surface of the mast (3 or 4 inches will be plenty) and bond the reinforcements firmly to the deck and hull, and all will be well.