Pearson Boats - Common Systems > Mast and Spar Issues

Replacing mast step bolts

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cpbova:
What is the preferred method to repair a stripped mast step bolt hole.  I currently have 3/8" galvanized lag bolts.  These are very rusted, so I am replacing them with 316 SS bolts.  While replacing them I had one that will not tighten. I have searched the web, but I cannot find any recommended repair procedures.  As I see it I can install a longer bolt, install a bigger bolt, fill the hole with epoxy or drill a new hole. Just wondering if anyone has performed this repair before and what they did.

Rusty Pelican:
Is your mast step the original powder coated carbon steel?
When I replaced my step some of the original screws would not back out.
My mast step screws were stainless. I sheared them off and ground them down flush.
I drilled new pilot holes near the old ones for the new mast step.

Dolce_Vita:
When I replaced my mast step with a welded aluminum one made from 1/2" plate, two of the galvanized bolts came out and 2 didn't, shearing off the heads.
Since the step had slotted holes, I just drilled new holes for the SS lag bolts.
Be VERY careful drilling lead, as it can gall up and sieze and break the drill bit.  Go very slow, backing out the bit very often to allow the flutes on the bit to unload.

cpbova:
Thanks for the advice.  Since my bolts came out I might just go up a size and reuse the same hole.  I think the step bracket will accept the larger bolts.

Captain Bri:
My old mast step is out and I am waiting for a new one from DC Products.  The old bolts are just stubs of rust, nothing left to grab onto, vice grips just turn them to mush.  I am reluctant to grind them down because it seems that the positioning of the new step is critical.  I was thinking of leaving the old bolts stubs in for alignment purposes and drilling four new holes in the slots when I test fit the new mast step. 

Any comments on this approach?

About how long should the new bolts be (how far into the sub-surface)?  Maybe 3 inches?

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