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Home >> Technical >> Is my RS Aero top mast broken see picture
I fixed a mast track that was dropped and cracked in a similar manner. West Coast Sailing provided a 1 meter section of track for the repair.  I still have all but about 15 cm of the track in case anyone in Seattle needs to do this repair.

Using a hack saw I cut the track square to the axis of the mast, then used a utility knife to cut the exposed adhesive allowing removal of the broken section of track.  In these two steps, I was careful not to allow the saw or knife to touch the carbon.
 
For alignment, I used a straight edge (4mm x 25mm x 70cm) laid into the groove of the existing track.  To stabilize the straight edge, I filled the rest of the track internals with several small dowels.  The straight edge and dowels extending from the good track formed a jig that ensured proper alignment between the two pieces of track.

After a successful dry fit and masking, I put West System G-Flex adhesive on the bottom of the new track section and slid it onto the alignment jig. Two clamps were used to keep everything secure while the epoxy cured.  After the repair, this upper mast was used all winter without any issues and is the spare for the Seattle Aero Fleet loaner boat.

PS. The post repair photo below was taken before installing the rivet at top of the track.


Reply
11/06/2021 01:14:00
MJohns77
Posts: 2
Agreed.
Where the cut-out us at the top (original post?) the assembler has simply attached it upside-down.


Reply
09/06/2021 08:09:00
Mark Ripley
Posts: 5
That is fascinating, it would be really interesting to measure both cut outs and see if they are identical.  I have a new theory, if they are identical then could the manufacturer have accidently used the track designed for another boat?  It would have to slip through QA of course.

Reply
09/06/2021 08:01:00
Robert Holdway
Posts: 10
Wow -- I don't think that cutout is supposed to be on the lower mast either! But it sure looks like the one that suddenly appeared on my upper mast. (For the record, I used the right sized sail -- 9 sail on 9 mast -- but there are other good theories here about what might have gone wrong.) Thanks to all for your help!

Reply
09/06/2021 02:53:00
dautor
Posts: 7
My 5 rig lower section which was bought a year or two ago new from RS has always had this 'cutout' too in the track - I just presumed it was there by design as it is so symmetrical as you pointed out David!

Luckily it is in the lower section so I will leave it as is, but I never thought to question it.


Reply
08/06/2021 21:57:00
tinkeratsea
Posts: 2
This is pure speculation, but I wonder if you could get this sort of damage if you inadvertently put a 5 sail on a 7 mast?  In any case, RS are excellent at sorting out any warranty issues.

Reply
08/06/2021 20:48:00
Robert Holdway
Posts: 10
David,
Sorry to see that.

I don't have experience of these breaking without reason. We do need to be careful when droping our masts to ensure we dont bash the track on anything. Another possibility might be if your sail dropped a little whilst sailing to that point so that the track was under extra load, with the halyard at a less supportive angle.

You would have to ask RS re warranty. They don't routinely monitor this forum, contact your local dealer in the first instance, otherwise RS Sailing Customer Support.




Reply
07/06/2021 18:55:00
Peter Barton
Posts: 3281
Has anyone else had an issue with delicate spars on the RS Aero? I've not capsized, crashed, or even trailered the boat. I believe that this "cutout" simply snapped off under load while sailing (and not in a hurricane). Argh. :-{

The boat is only 8 months old. I wonder if RS would consider a warranty replacement of the upper mast...


Reply
07/06/2021 15:55:00
dautor
Posts: 7
Thank you, David. I'll do that.



Reply
07/06/2021 13:28:00
dautor
Posts: 7

Have a chat to RS for the right things - but you need a section of new mast track and some glue! The old mast track can removed so should be a fairly cheap fix. 



Reply
07/06/2021 09:32:00
David-at-BroadwaterSC
Posts: 35
Dear RS Aero Sailors,

I just noticed a "cutout" in the sail track at the very top of my RS Aero top mast that I never noticed before (see photo). The cutout is sufficiently symmetric that it almost looks like it's supposed to be there -- but I fear that it's not. I don't recall seeing it, and I don't know what purpose it would serve.

Does this look broken to you? Gulp.

Thank you
David

 


Reply
07/06/2021 00:04:00
dautor
Posts: 7


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