Sailboat Spars Mast-Head DIY ProjectsSailboat spars and making our masthead, We have a aluminum mast, so our masthead will be made out of the same material. A Reciprocating Saw, Circular Saw, Jigsaw, with any of these tools you can cut the mast. In the following pictures you will see that it is not a challenge to cut through this metal.
T6, means it was heat treated, (T6 Solution heat treated and artificially aged) for example, 6061-T6. You will notice that the top of the mast where the masthead sits. This grade of alloy 6061-T6, has a yield strength of 40,000 p.s.i. (pounds per square inch) and a shear strength of 30,000p.s.i. Key: A high number after the T, means high strength for that alloy. There is a 7000 series alloy used on high-performance racers, (where a very small mast section is used) Key: Important information, transverse and longitudinal moments of inertia...term inertia is used to mean resistance. Webster's Dictionary:
Inertia means here: tendency not to move or act
How much pressure (inertia) would it take to crush a beer can?
Use only fastening metals that are compatable with aluminum, you want to avoid galvanic corrosion. Do not use copper or bronze with aluminum. Galvanic Series, List of least noble to most noble metals is: Magnesium, zinc, aluminum, cadmium, steel or iron, cast iron, stainless steel, lead, tin, manganese, bronze, brasses, copper, (copper paint), silicon bronze, (everdur), monel, nickel, silver, graphite, gold, mercury (mercury paint) Sailboat Spars Magic Dragon coming next...
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A scratch line notched into the aluminum helps show where we needed to make a cut. The line is a lot thinner if you don't use a marker. Use a straight edge when scratching your line.
Heat treated Aluminum, carry a “T”,
This is the masthead we are welding together to be placed on our used sailboat mast.
Notice all the c-clamps, and blocks of wood...these hold. everything together while the welding takes place. The aluminum wants to move, contract and expand while it's heated
