Mast issues and repair

The excitement of the past week has been a breakage in the rigging system.  One of the eye bolts which run through the top of the mast sheared open, and the mainsail and yard came crashing down on the leeward deck.  Sally and the dogs had been aboard at the time and, in quite spicy conditions, I had only moments earlier asked her to come and join me on the windward side, thus avoiding any injury...

Sheared Eye bolt at the masthead which previously held a block facilitating the yard uphaul.

Fortunately, the unstayed mast stayed firmly in place.  Nevertheless, the mast had to be transported home for some repair work.

Carbon fibre damage, mainly caused due to the incorrect mounting of the eyebolts - some penny washers might have helped...

Closer inspection showed that the previous owner hadn't mounted the M8 bolts correctly, neglecting to use penny washers and meaning that the underlying carbon fibre had been compromised.

The advice from Alex at AYB was to remove any carbon splinters, glass round a section of fibre tape.  I did this both inside and out for good measure.  I then redrilled the holes.  

I'd never previously used glass fibre tape, but had used epoxy.  Having previously watched plenty of videos only, the repair was managed with ease and I'm quite pleased with the strength of the repair.  For good measure, I put fibre tape both inside and outside the masthead.

Finally, a job which certainly needed doing, the mast was clothed top to foot in shrink wrap - lucky I had a heat gun to complete this job.  This not only enhances the look of the mast, but offers some really helpful UV protection for the carbon fibre - hopefully significantly adding to its longevity.

It's necessary to leave the bottom section unsheathed since this is the bit that goes down into the deck.

I sourced this through Hilltop Products.  5m of 101.6mm Inner Diameter tubing (before shrinking), with a 2:1 shrinking capability - more than sufficient for this 80mm diameter mast.

I sourced some brand new M8 through bolts from s3i online - two were required - since the originals had been bent.  I also sourced appropriate penny washers at Fox's which will hopefully prevent further damage to the mast - at least spreading the stress across a wider area.  I also took the opportunity to epoxy the top bung, which is now rather more firmly wedged in place.

The repair was tested out yesterday with a gentle sail from Pin Mill.  

I also took the opportunity to change a few aspects of the rigging, most notably a piece of cord which is designed to hold the boom to the mast and catch it when it falls.  I have now copied the rigging from a few other boats to see if it improves matters.

Daisy IV at the jetty at Pin Mill.  Repaired mast fully rigged and tested.

Sail up - it all works...!

Red track 3.7nm - this was from August 9th, when the rigging broke.
Yellow track from August 14th - 4.7nm - a successful test of the repaired rigging