The bow end of the upper spar mast cap and interlocking bolt pulled out of corroded holes, so we pulled the caps off, rotated the spar 90 degrees, and reinstalled cap and interlocking bolt in fresh metal.
Dissimilar metal corrosion between the aluminum spar and stainless interlocking bolt is common around our salt waters, fresh water rinse downs are helpful preventative maintenance.
Rotated the outhaul cap 90 degrees.
Made sure the new holes would be oriented correctly with the outhaul cap and drilled new holes for the interlocking bolt with a 7/16th inch drill bit. You might notice in this picture that we installed an outhaul cap on the bottom spar (boom), that way if the spar drops down onto the deck there is plastic material rubbing the deck versus the metal interlocking bolt end. Many a Sunfish have half moon scratches on their foredecks from those bolt ends. A couple of wraps of gaff tape could also cover the bolt end.
Reinstalled the interlocking bolt, secured with a nylon lock nut.
Probably should take BOOMER out for Sea Trials again, to check our work. I'll write up a test card for the Skipper.
Log of BOOMER aka SUGAR 2.
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