Selden Sealing of Keel-Stepped Masts — Service Manual

Before You Start

• First check the leak is not external: poor sealing between mast coat and mast wall, or holes in the coat.
• Work in dry weather. Mask deck, mast, collar and the keelson area – the compound tends to flow out. Divert halyards and lines.
• Read the safety data sheet supplied with the epoxy compound.
• Warning: start with a small amount (<100 ml) and watch inside the mast and at the heel below deck. If it leaks through, pour small amounts and let each set before the next.
• When drying the mast, never heat it above 100˚C – overheating can reduce its structural integrity.

Not in the Kit

• Methylated spirits (ethanol), acetone
• A scale, containers for mixing, stirring pins
• Ø8-10 mm drill bit, Ø25 mm hole saw, knife
• Cleaning cloth, heavy steel wire (internal cleaning)
• Small torch, hair drier
• Masking material, measuring tape, transparent adhesive tape

Conventional Masts

1. Drill one Ø25 mm hole approximately 50 mm directly above the existing drain hole on one side.
2. Clean inside with steel wire, cloth and ethanol; dry with a hair drier.
3. Tape over all drain holes. For the sail slide compartment, tape the sail groove between collar and kicker fitting leaving a ~5 mm gap; plug the lower kicker rivets with the enclosed plastic plugs if needed.
4. Pour a little at a time to a total of 5-10 mm.
5. Remove tape and clean with acetone while the compound is semi-set (not fully cured).
6. When cured, re-drill drainage at an angle with an 8-10 mm bit through the old drain holes, right through the epoxy; drain the sail slide compartment just below the kicker fitting if needed.

Furling Masts

1. Drill a Ø25 mm hole into one or both compartments, approximately 50 mm above the drain hole(s).
2. Clean and dry as above.
3. Tape the drain holes and the aft face opening; plug the lower pop-rivet holes in the kicker fitting.
4. Pour to a total of 5-10 mm; clean off with acetone while semi-set.
5. When cured, re-drill drainage at an angle (8-10mm). Remove the tape, leave the plugs.

Alternative: inject through the existing ~10 mm drain holes with the enclosed plastic bottle instead of drilling Ø25 mm holes; tape one side, inject on the other, fill 5-10 mm and tape the injection hole quickly. Masts produced between 2002 and 2014 have a different drain hole pattern but usually take the same procedure.