Mast Problem - Forestay Pin Hole

Tom Olsen · Post by **Tom Olsen** » Wed Dec 01, 2004 12:09 am

For the last 7+ years, our 1982 7.9 has gradually worn a larger hole in the mast tang where the forestay pins. It is now somewhat oblong. I have been warned not to fill-in the hole with weld and re-drill because of changing the temper in the aluminium. Has anyone had this problem and have a good fix?

Also, I was wondering - in case of mast breakage, how do you replace an Offshore mast when they don't make it anymore?

Tom Line · Post by **Tom Line** » Wed Dec 01, 2004 2:31 pm

NEWJSI in Tampa / St Pete is doing the masts. You can google their web site pretty easily.

As for the tang, if it's worn enough, can you drill it out a small bit and just put the next larger side clevis pin in it?

You could also ask NEWJSI if they will sell you the tang seperately.

Post by **Tom Elsen** » Thu Dec 02, 2004 11:41 am

Just to provide a bit of clarity on the 'mast' issue.

The Class Association (the members who pay for this site, sponsor and make possible the one-design events we all love, who pay for the newsletter, and the insurance and, and, and), that Class Association, owns the mast blanks. Members paid in excess of $10,000 for the die and for the extrusions.

The class association will sell mast blanks to S2 7.9 owners only. JSI then fabricates masts (from those blanks) to class standards.

Please be aware that the price charged to members is VERY different than the price charged to non-members. And, in order to get the member price you must be a current member of the Class Association and you must also have been a member for the full year prior to the placement of the order.

Guest · Post by **Guest** » Thu Dec 02, 2004 1:55 pm

Way to go Tom!

Thanks, whoever you are. But the real credit is due to a bunch of people who really make things happen. Dave Grover. Jeff Mootz. Mike Bremmer. John Leyland. Paul Latour. The Boston family. The folks who contributed to the mast fund. The guys who have stepped up and organized / sponsored events like the midwinters and the CCR. The folks who post great info for all to read on this site. AND MOST OF ALL, the folks who pay for all of this stuff -- the members!
Tom

Rudeman · Post by **Rudeman** » Sat Dec 04, 2004 4:11 am

Tom,

Great point about class dues....Sounds like a good time to post the 2005 class applications. As always, thanks to those who work hard and volunteer lots of time to keep things alive - you effots are very much appeciated.

Stef · Post by **Stef** » Sat Dec 04, 2004 5:12 pm

Guest saying "Way to go" was Stef. I was on a remote computer and not logged in. Tom Elsen couldn't be more correct!

David Grover · Post by **David Grover** » Sun Dec 05, 2004 4:43 pm

Back in about 1998 S2 did a retrofit of the clevis pin on the forestay with a 3/8 inch pin. It increases the bearing area. You may have to drill out either the tang or the jaw to this size. A 1/4 or 5/16 inch pin in a 3/8 inch hole is not a good idea.

Dale Eager · Post by **Dale Eager** » Mon Dec 06, 2004 8:26 pm

David Grover wrote:Back in about 1998 S2 did a retrofit of the clevis pin on the forestay with a 3/8 inch pin. It increases the bearing area. You may have to drill out either the tang or the jaw to this size. A 1/4 or 5/16 inch pin in a 3/8 inch hole is not a good idea.

Dave, very interesting! When I replaced my standing rigging this fall I noticed the hole in the mast was a bit elongated and pin was loose. The toggle and pin on the top of the forestay were 5/16", but a 3/8" pin fit the hole in the mast tang. I then checked the specs in my 1982 owners manual and the spec for the forestay is "upper fitting, #6 toggle, lower fitting, #6 turnbuckle". So I concluded that sometime in the past someone replaced the forestay with the incorrect (5/16") toggle on the top. But if what you are saying is correct, perhaps they were supplying them with the wrong toggle during the original production run of the boat (1982-1986)? In any case, I had my new forestay built with the #6 toggle (3/8" pin) on top and it fits very well with no drilling necessary.

Dale Eager · Post by **Dale Eager** » Wed Jan 31, 2007 12:01 pm

Replying to bounce this to the top in response to a new message posted by grand illusion.

I pulled the pin in December when I dropped the mast. Three years later and the 3/8" pin is still nice and snug.

BarryE · Post by **BarryE** » Wed Jan 31, 2007 7:10 pm

I'll be running out to the garage and taking a look at mine tonight;
original mast, original forestay; hull#11
I'll let you know what I've got.
Maybe we can clear up the confusion.

BarryE · Post by **BarryE** » Sat Feb 03, 2007 11:28 am

Checked mast and discovered; 3/8" hole, 3/8" pin. Conclusion; either the factory got it right on my mast, or the original owner switched it to 3/8" long before I had the boat.

Nice work on this thread Barry. Thanks. Tom.

grandillusion · Post by **grandillusion** » Mon Feb 05, 2007 10:03 pm

OK I was at my boat Sunday. it seams that the mast had a 3/8 " hole at one time but the prior owner/s have had a 5/16" pin in it for some time, the present hole in my tang is pretty elongated, can I TIG weld it (to fill), or will it hurt the temper? aluminum oxide infused West System to fill the gap????????

dhobbs · Post by **dhobbs** » Tue Feb 06, 2007 11:07 am

You can TIG weld it and redrill and it will be just fine, I have a metal
Fabricating business do this all the time

S2 7.9 Meter Class Association

Mast Problem - Forestay Pin Hole

Mast Problem - Forestay Pin Hole

Masts

2005 Dues

Mast forestay tang hole

Re: Mast forestay tang hole