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John J.
Navigator

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USA
157 Posts

Initially Posted - 05/07/2005 : 16:05:17

Today, when I was removing my spreader brackets, I was relieved to find that the bolts moved freely and I wasn't going to have to deal that frozen bolt/compression tube scenario that I've read about on this forum. That was the good news. The bad news is, there is no compression tube. I guess that's why I have no corrosion. Maybe one of the PO's, (who now have me PO'd), dropped it while doing an upgrade. As I was removing the bolt, I was careful to follow through with a screwdriver so the tube wouldn't fall, ( had there been one). There's no way the mast came without one, right? Anyway, the boat sails fine without it, but I will endeavor to to add yet another project before launching.

Any advise is appreciated.

1987 C 27
#6387

Edited by - John J. on 05/07/2005 16:05:52

Buzz Maring
Master Marine Consultant

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USA
1773 Posts

Response Posted - 05/07/2005 : 17:54:10

<font color="blue">... There's no way the mast came without one, right? - John</font id="blue">

Well, I'm not so sure about that. When I replaced the spreader brackets on my mast, I think there was only one compression tube installed out of the three available bolts ...'don't know if that was the "factory standard," or a PO's "project" (although there was no evidence that any PO ever did anything to the mast ... it still had the old aluminum brackets, 'no anchor light/wiring, etc.). I went ahead and installed compression tubes for all three bolts (I'm pretty sure that Leon did the same thing ... maybe he'll see this thread and respond).

I have to say, installing the compression tubes is a bit of acrobatics and luck all rolled into one. Someone else recently installed compression tubes, and I think their solution was a good one. I'm no engineer, but it seemed OK to me. Their technique was to drill a very slightly over-sized hole in the mast, i.e. a hole big enough to accomodate the compression tube. Simply insert the tube in place through the hole, then secure the spreader brackets in the normal way. I really don't see why that wouldn't work.

Nevertheless, I did it the Neanderthal way. I bought a long section of PVC pipe (1/2", I think) ... I don't recall exactly how long it was, but I think it was 12' ... at any rate, it was long enough to reach from the bottom opening in the mast up to the location of the compression tubes. I used some masking tape to secure the tube to the end of the PVC pipe, and then I "snaked" it up the inside of the mast. It was a real challenge to get the tube lined up with the hole, but I finally got them all done (solo, I might add ... it would work better if you had someone to work at each end). Once each tube was in the proper position, I simply twisted the PVC pipe back and forth until it broke the masking tape.

Like I said, I really think that the over-sized hole is the way to go. If you use the "Neanderthal" way, you have to snake it past everything that protrudes into the mast (screws, halyards, wires, etc.), and there is always the chance that you'll get the tube hung up on something ... if the masking tape breaks before the tube is in the proper place, I have NO idea how you're going to get it out to start over again (short of raising the mast and praying that the tube falls out of the end of the mast).

OK ... 'hope that helps ... good luck!

Edited by - on

Buzz Maring
Master Marine Consultant

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USA
1773 Posts

Response Posted - 05/07/2005 : 18:04:43

Hi John,

One additional thought ... if you decide to drill the over-sized holes for the compression tubes, I think I would use the smallest size compression tube I could get away with ... in other words, the compression tube should be just big enough to accommodate the bolt used to secure the spreader bracket.

The reason I brought this up is because I seem to recall that at least one of the compression tubes supplied by CD is BIG ... 'like about 1/2" in diameter. I think that three BIG holes drilled in the mast for three BIG compression tubes might weaken the mast ... that's why I would go with the smaller tubes. Other than that, the hole-drilling method sure seems like a good way to go ... 'hope I'm not giving you a bum steer.

Let us know how it turns out!

Edited by - on

Leon Sisson
Master Marine Consultant

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USA
1893 Posts

Response Posted - 05/07/2005 : 20:21:53

John & Buzz,

When I upgraded the spreader brackets on my 1979 standard rig, I installed four compression sleeves. One around each of the bolts, and a fourth one in line with the spreader bars themselves. That fourth one came from Catalina with the SS spreader bracket kit, and seemed to have been cut from the same tubing as the spreaders. The other three I made up myself out of aluminum tubing with thick walls and inside diameter maybe 1/8" larger than each bolt to spread the load, and to prevent the stuck sleeve problem in the future. I coated the inside of each bolt sleeve with lots of waterproof grease as I recall. I worked the sleeves into position using the PVC and masking tape method. I cut a V-notch in the end of the 20' piece of PVC to help retain and steer the sleeves.

I can see the appeal of the "drill bigger holes in one side of the mast" method. However, when masts fail, they almost always do so exactly at the spreaders. The whole idea of the compression sleeves is to reinforce that area. I'd be very reluctant to remove any additional metal from the extrusion there. With the "drill big holes" method, it would seem to me that the small hole side wall of the mast is going to have to withstand heavier cyclical loads, and since the compression sleeves have to be so small, the loads are going to be more concentrated than if larger sleeves were used with the original size holes. But hey, I'm not a mechanical engineer. However, I'd assume the folks who designed the rig in the first place might know a bit about such matters, and in spite of their strong incentive to minimize labor costs, they slid the sleeves in from the end.

-- Leon Sisson

Edited by - on

John J.
Navigator

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USA
157 Posts

Response Posted - 05/08/2005 : 09:56:11

So the original mast came with three, not one compression tube?

Edited by - on

ct95949
Captain

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Aruba
300 Posts

Response Posted - 05/08/2005 : 12:15:51

Hi John

This is definitly not one of the 'fun' upgrades

However, the secure feeling you will have of your mast makes it worth the effort.Without the tubes you can dent the mast as you tighten the bolts,with tubes it will be rock solid.

When I installed mine I taped the two CD tubes and a 3/4" brass pipe nipple (all cut to the mast I.D.) to a length of 1" PVC then slid into place.The three tubes together go in easier than one at a time,the brass is a perfect spacer for the other two and the result is continuous solid support through this critical area.All parts were coated with grease.

Measure everything carefully first-I did this two months ago and may have used 1" brass.The big bolt and one of the small bolts went through the tubes at each end.The brass is taped between the other two and won't go anywhere when the bolts are tightend.

I refuse to drill one more hole in my mast.It looks like swiss cheese after removing the PO's old hardware.I want to find a way to fill these holes and make the mast stronger.

Edited by - on

bbriner
Captain

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349 Posts

Response Posted - 05/08/2005 : 12:26:18

John J -
The schematic that CD sends with the spreader bracket replacement kit, which appears to be a copy of the Catalina original, indicates two compression tubes. One large tube is inserted inside the mast between the two upper bolts. There is no outside holes drilled through the mast for the big one (it must have been snaked through the mast as Leon describes), nor are any compression tugbes indicated fgor the two upper bolts.

The lower bracket bolt (which, btw, is the larger than the upper two) is inserted through a small compression tube that is approximately 1/2" in diameter. The adamant advice of a local rigger was that the best and most convential way ('the only way') to install the lower/smaller tube was to drill two holes in the mast the same diameter as the tube and insert the tube through these holes. The tube must be cut equal to be very very slightly less than the outside diameter of the mast at this point so the tube takes the full stress; and it must be filed flat (90 degrees).

I think you'll find that this method is much easier.

Bill B
Wind Dancer
84C25 FK/SR #4036
pics at http://www.pbase.com/bbriner

Edited by - on

takokichi
Captain

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USA
321 Posts

Response Posted - 05/08/2005 : 18:57:22

For whatever its worth, my boat - 1980 SR/FK #1942 came with NO compression tubes. They're there now, though!

Edited by - on

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