E43 Ketch Maststep Leak
Date: June 5, 2001
From: Joyce M. Parmar jmparmar@home.com
Major leak into aft cabin from foot of mizzen mast, tracks across to starboard side above vanity. The wood behind and above finishing has rotted somewhat. Other than removing the mast does anyone have any suggestions.
Date: June 7, 2001
From: Stuart Phillips StuP@aol.com
I have an Endeavor 43 Ketch. I have had exactly the same problem. Unfortunately we found that we had to take down the mast and rebuild the support to the compression post. We found that the problem was in the support of the mast by the compression post.
At the same time we took down the after Hatch and recaulked it. It has not leaked since.
I found that there were also leaks around the main mast. You should check the I beam that is the support of the main mast for rust. Some of the original supports were shipped without galvanization. They rusted and needed to be replaced.
The other Hatches need to be taken out and recaulked at regular intervals or they will leak into the headliner also.
I hope that someone has a way of fixing it without taken the mast down. If they do please copy me. If not let us know how it worked out.
Date: November 2, 2010
From: Donald Chisholm
I have a major leak into my aft cabin and I belive it is from the area of the Mizzen mast support, has anyone had this experience and if so what recommendations would you make to fix it without having to remove the mast to gain access to the fibreglass support structure.
Date: November 2, 2010
From: Bruce McCampbell
Don,
Have you removed and re sealed the aft hatch. The other place it will leak is the boxes in the aft wall of the cockpit. The mizzen is stepped on a solid chunk of glass that would only leak if you hit a bridge. If the overhead is original, then it is a solid piece of plywood. A leak can start on one side of the boat and run to the other. Try to remove the starboard aft box to gain a visual access to the leak area. Apply the water and if you can't see the leak, then it is coming in under the trim on the aft hatch. You can remove and replace the hatch and trim from the outside.
Bruce
Date: November 2, 2010
From: Andrew Loughrin
I also have a 43 and had a problem with a leak that I did not notice until I pulled the masts. I think the water was from the rain that comes down the inside of the mast and follows the wiring into the boat. The structural support for the mizzen is inside the fiberglass and is wood and hard to get to. Your boat may have a inspection plate on the backrest in the cockpit threw which you can inspect this area or you may need to cut one in. What happens is the mizzen support rots out and then the mizzen looses it's connecting support to the newel post in the aft cabin. If allowed to exist for a time the aft cabin top starts to deform from the pressure. If you inspect yours and find that you have problems with rot then get back to me and I will share with you one of the fixes. (Not much fun)
Good luck Andy
Date: November 2, 2010
From: Craig Hunter
This is a common problem on 43K's. The mast will need to be lifted and reseated. Sikaflex is the best but make sure the glass structure isn't cracked.
Date: November 2, 2010
From: Bob Leahy
Don,
If you are speaking of the mizzen supports on the toe rail. remove the screws on the top stainless plate on the toe rail where the stay connects to the chain plate. The caulking that was initially installed in that area has dried up. Clean the residue in the toe rail and then using "life caulk liquid sealant" fill the hole to the top of the toe rail. Let that cure for 24 hours and repeat until the liquid caulk remains proud of the toe rail. It will take several applications to fill in the void that surrounds the chain plate as it penetrates the toe rail and cabin top. I would recommend that you look at all of the chain plate covers and follow the same procedure for each.
I chased several leaks for two years and when I stumbled on to the void around the chain plate, I was amazed.
I hope this help..
Bob Leahy
E43 Scruples
New Bern, NC
Date: November 2, 2010
From: Donald Chisholm
Thanks Bob,
I have encountered that problem in the past and did exactly as you did but what I am talking about is the fibreglass structure that the mizzen mast sits on, it appears to be the place where water is ingressing, I dont know what the mast steps on but I assume it is the standard mast step and perhaps the bolds have rusted through or the caulking has deteroriated.
Date: November 2, 2010
From: Donald Chisholm
Thanks Andy,
That has answered some of my questions..what is behind that fibreglass support, I would be glad to hear of your fix
Date: November 2, 2010
From: Donald Chisholm
Thanks Craig,
I was afraid that would be the only way out.
Date: November 2, 2010
From: Capt. Paul West
Donald,
I've got that leak too... It comes down over the desk area in the aft stateroom. I've gooped up all the spots that I can see and now I'm wondering if there is a direct hole in the top of the mast that is letting the water come down the inside of the mizzen mast and exit in the aft stateroom on the starboard side over the desk. It's a heck of a leak and it has to be coming from the mast, hardware or anything that is above the stateroom.
Maybe the wenches or traveler or... Let's keep this dialog up so we can take care of this situation...
Date: November 3, 2010
From: Remi Marenette
Hi,
Had the same problem and found that I had to put sealer under the mizzen support and that cured it.
Remi
S/V Free At Last (Formerly Calypso's Ketch)
Date: October 14, 2015
From: Wolfgang Harms
When I had a new mast and mast step installed the mast had an internal moisture barrier above the deck and a drainage hole. To install such a barrier and drainage hole into a stepped, existing mast, I would cut a hole, say 1” diameter, stuff any material like rags into it below the level of the hole, insert a hose ¼ to ½ “ , spray lots of PVC foam into the hole (the rags preventing it from running down), adjust the hose, and screw a cover plate to the mast with a hole fitted to the drainage hose. You might try it before closing by hosing water inside and check that no water leaks out of the step.
The original mast step had corroded away and the mast broke off in hurricane Ivan.
Good luck
Wolfgang
SeaLife E43
Date: October 14, 2015
From: Craig Hunter
I’m guessing we’re thinking here about the mizzen mast? The main is another issue. Paul, I posted this repair back a few years ago on the FB page when I was active there. There is no "quick“ fix for this issue. The cause is two-fold. One, water leaking down the mast is running through the mast wiring chase in the mast step due to improper installation of the mizzen. Secondly, the mast step itself may be damaged do to stress fracturing.
There are a number of ways to repair the preceding issues, but ALL require the removal or partial removal of the mizzen.
- Check that the compression post support has not rotted away and the compression post has dropped allowing the weight of the mizzen to loaded directly to the deck causing cracks to form along the mizzen step, as it happens to sit where water from leaking rub rails or condensation flows to the bilge. Note, the compression post cannot be removed with the mizzen installed.
- If the compression post checks out, then remove the mizzen, do any required repairs making sure to seal all openings with Sika-flex, or any quality poly sealant. Do not use ANY sealants that employ silicone or 5200. Important, when re-stepping the mizzen, seal the wiring chase liberally with plumber’s caulking (good because its easy to get the wiring back out if removed seasonally) or Sika-flex (better but a bit tricky if the mizzen has to be removed seasonally but make sure there’s enough wiring bundled on the mast side to allow the mast to be lifted and the sealant removed). Ensure there’s a weep hole drilled (3/8“) through the mast and mast step to allow moisture to escape to the deck. Replacement of the mast step plate may be required and are available from Rig-Rite.
- If the mast step is cracked, remove the mizzen, remove any paint then grind out the damage following the cracks. Make sure to inspect the base of the step hidden inside the combing for any damage and repair accordingly. Fill and fair the cracks with West System SIX-10 or Thixo (Jamestown). If needed layup some cloth to reenforce the step and finish. Apply the same installation of the mizzen as noted above.
The basic repair by sealing can be done with a short lift if you’re prepared and don’t want to remove the mizzen as it requires removing wiring etc. Access the base of the mast step through whatever manner is installed, lift the mast from the step feeding the wiring through the chase about 1 foot and do the sealing repair then restep without removing the mast completely.
Cordially,
Craig Hunter
Date: October 14, 2015
From: Dan Rich
Mine was leaking, not from the mast, water was leaking from the glove box
run on cabin ceiling down on to vanity, figured it was the chain plate.
Removed headliner seen the leak. As far as the mizzen it was not leaking,
had leak forward head, it was from the forward hatch, air pockets in the
fiberglass water ran through the fiberglass, came out in the forward head
ceiling. Finding leaks is hard. I finely solved all the leaks on my 43.
Hope this helps.
Date: October 14, 2015
From: David Burford
I don’t know what you guys have found but my mast step ( the 4 ft long 8 inch u channel the mast sits on) is totally gone. It's rusted right through so I cut it out of the boat and the mast is presently sitting on a lump of epoxy and “mine Tailings” as Bernie Katchor put it. The long U channel is not necessary as my rigger recons its only so they can change position from the two mast to one mast version of the craft. I’m still pondering the whole question of the mast step. I think I might dig it out and build a reinforced base similar to most other boats. I'm not sure wether you have cottoned on to the fact that the mast hits the hull right at the point where the keel diverges off. An interesting spot but not on the lead. ??? what are your thoughts on it all.
Date: October 15, 2015
From: Don Freeman
I haven't read the article so this may be duplicating.
Our step was rusting and I was worried that the rust would eventually weaken the supporting base. Therefore we decided to repair rather than replace. We followed the following steps: I ground out all the rusted parts possible to reach. I then applied an epoxy rust preventative. Then built a dam of wood and epoxied it forward and aft of the step with two 1-inch pieces of pvc conduit run from the forward dam through the aft dam, such that any water collecting from wet anchor chain would drain aft to the bilge. Then I mixed concrete and poured and packed it into the dam space, floating it till it was the same height as the top of the beam. After at least three weeks of curing, I mixed West systems epoxy and coated the entire exposed surfaces, building up some thickness on the top. Cost was minimal and no cracking or bleed through of rust was ever noted in the following 7 years of cruising.
Subsequent owner has not reported any problem. From a compression analysis, I calculated it could stand 140,000 pounds of force, ignoring the steel reinforcement.
Good luck.
Date: October 23, 2015
From: David Stubbs
I had the same problem and followed the thread, which didn't work.
The mast as you know is stepped on a big piece of fibreglass, unlesss you see a big crack it is unlikely it is leaking from the step. Just below are two air vents, check these and replace and bed properly. Below these, and this is where i found my leak, is the hatch which is held in with bolts and screws through the deck. Anyone of these can leak, I sealed it all from the outside and I still got leaks, it has to be taken up and rebedd to fix the leak. I was lucky as I had taken down all the ceiling in the aft cabin and it was easy to fix.
Over the last year I've completely gutted my E43 of all the plywood, ceilings and flooring leaving only the hardwood. I know a lot more about the boat than i wanted when i bought it. The only thing I would be really careful of are the chainplates, they all looked great above the deck but everyone of them was cracked where the bolts were attached.
