David Webb wrote:

Hi Jason,

there is also the option of hurricane rated aluminium flagpoles. They seem to be readily available in the USA at a reasonable price and they would be less flexible than the fiberglass ones. I believe that they can be manufactured up to 43 feet long in one piece including the entasis taper, longer lengths need a splice. They are 6063 T6 and can be powder coated or anodized.

All the best with the restoration, David.

Thank you David!  That's a good suggestion if we are not able to salvage our wooden masts.  From what I hear fiberglass is going to bend too much.

Are the masts solid grown, or glued up from sawn timbers?  It's possible that they are effectively trees that have dried out in the boat.  In that case, the shakes, assuming that there has been no serious water ingress, are not an issue.  By now the masts are properly seasoned, and it would be possible to fill the shakes with epoxy, microfibres and microballoons before sanding them down and covering them with one layer of fibreglass, after which they would be coated with some more epoxy and then painted.  I would follow David's suggestion of enlarging one or two of the shakes to see if there has been any damage, first.

The fibreglass flag poles sound interesting, but a lot of flagpoles seem to work on the principle of 'what bends don't break'.  However, the mast on a junk rig needs to be very stiff, so it would be worth seeing if you can find any photos of these flagpoles in action, flying a big flag on a windy day.  But USA is also, apparently a good source of alloy light poles which may be stiffer.  Look on the fora and Junk Information/useful links for more information on these.  There is also a mast database, from which you might glean some useful information.

David Thatcher wrote:

I think you would certainly want to know the extent of possible damage to the masts before putting any more time and money into repairing something which may still let you down just when you need reliability. Unfortunately you may never be able to know looking from the outside just what is going on inside the masts. One option might be to cut out one of the larger splits with a 'v' shaped cut and see what is happening further into the mast. You would then be able to scarf back in a suitable piece of timber which if it is well glued with epoxy should not take away from the mast strength. 

It might be better in the long run to just cut your losses and start again with the masts. Fiberglass masts sound interesting. I have two friends (brothers) who between  them have a pair of cat rigged cruising yachts, one of which has been offshore. The masts are unstayed and they self built these from fiberglass. So for them the fiberglass masts have been successful. You might also have a look at what David Tyler has been doing with his Hybrid mast build which could be another option for you. 

Thank you David.  I appreciate the feedback.  I'm working with some really great guys at the boatyard in Ventura and I'm leaving it up to them.  Hopefully they can be saved but if they have concerns they definitely will let me know.  Good to know I have options.  New glass sticks are almost more reasonable than repairing the old wood ones.

So we're well on our way to restoring Etoile du Sud (34' JR Jay Benford Badger design) and it appears as though the splits in the masts are particularly deep.  The originally wooden masts were pretty rough when we got them and were covered with a thick layer of epoxy where the damage had occurred.  Not sure about possible water infiltration but it certainly looks possible along these splits as well as some of the others lower down along the mast.  Do you think we should replace these with fiberglass flagpoles (American Flag Store)?  


Appreciate the feedback.


Jason

(Looks like I'm unable to post the pictures of the masts on this forum).  If anyone wants to evaluate them let me know and I'm happy to email you what I have.