Radar Mast Under Construction

[Vincentc]

I have gotten past the study and design stage and am actually building something. A plywood mast may seem a little different, but I believe it will work. Rather than wait, I will start posting pictures as things progress. The photos should tell the story.

Parts cut (1088 plywood) 8' mast 4"x8" at bottom, 4"x4" at top, to be mounted on 2.5' high base. Radar dome in background, will mount fwd of mast and above bimini.

Epoxy 7/8" strips to one fwd / aft piece.

Strips glued to both fwd and aft sections

Fwd aft pieces nailed and glued to side piece

 

[Vincentc]

Both sides attached to fwd and aft sections. 4"x4" Top closest to camera.

Bottom of mast, 8" x 4".

The pieces are held together with thickened epoxy and 3/4" x 18 ga ss brads driven by a pneumatic nailer. 9mm meranti plywood sides and 12 mm nailing strips will allow me to round the edges with a router and not hit the brads with the 3/4" round over bit.

to be continued

 

[Vincentc]

The corners are rounded, and sealed in epoxy. I am starting on the base support for the mast. The base will provide a little extra storage as well as some stiffening.

8 foot long mast weighs 25 lbs and will support my weight in a load across a 6 foot span.

 

[Vincentc]

The base for the mast is almost complete. It will be held by the large stainless steel hinge in the front and at the rear of the mast base it will be held by (2) 3/8" stainless rods passing through the ss washers imbedded in the base and through the bottom of the mast. The hinge will allow the mast to pivot forward, if ever vertical clearance is an issue.

Regards,

 

[Vincentc]

Starting to take shape.

Quick and dirty drill bit alignment for hole through mast for locking pin.

profile.
Does this rake for the mast look right?
I can change the rake up until I secure and glue the mount for the radar.
I am now working on base for radar dome and will then finish and paint the wood with Brightside Hatteras Off-White.

Regards

 

[SKYCHENEY]

Now you're gonna have to order new T-shirts with the new look.

 

[Vincentc]

Sky,
Fortunately, I was saved from that problem. Jack asked me about that conflict before I finalized the order.

I contacted Doug and he very graciously agreed to change the drawing to incorporate the mast, once I send him a photo with the mast. You don't find that kind of customer service just anywhere.

Regards,

 

[Pascal]

I think I would give it more rake. Adding spreader for flags and maybe spreader lights would be nice

Another approach to masts is to do a tapered birdmouth which will give you a rounded or oval shape with a taper. This is what s often used for sailboat masts but can be used for just about any spar incl radar masts. It s basically 8 strips with a 45 deg cut on edge allowing the strips to snap together

 

[TopHattandTails]

Vincent - nice project. Looking good thus far. How would it look if the rake was similar to the angle of the ladder beneath it? sort of an extension of the ladder on the FB.

 

[Vincentc]

Mast spreaders are planned. I can picture flags flying from the mast.

 

[sgharford]

Looks Great! You sure know how to have fun with your boat. I would second raking back a bit more. Just another 2 cents - I would not make any higher than it needs to be. I installed full aluminum radar arch on my 43DC. The extra appendage and height all the way in the rear makes the boat look that much ‘heavier’ in rear. The whole aft section (FB and Radar Arch) looks like a misplaced skyscraper on the outskirts of a small city - weird analogy, but it (kinda) does.

 

[Vincentc]

I attached the radar dome mount and dome and set it up for some photos to send to Doug Langley for our T-shirt project. It was a little challenging handling the mast with the radar dome attached. Thankfully nothing got away from me and we should have the shirts for Christmas.

I still have a fair amount of work to do rounding corners on the base, anchoring the base, filling and smoothing surfaces and painting every everything, but I am please with the result. I like the mast better than an arch.

A 3/8 shim under the fwd end of the base added to the rake..

 

[Vincentc]

Spreaders added, Hatteras off-white, and a little more rake.
Hope to mount the radar tomorrow.

 

[SKYCHENEY]

Looks very nice. Thanks for the pics.

 

[Vincentc]

The dome is mounted, masthead light, and spreader lights attached.

 

[Vincentc]

I put some of the VHB tape to use making the LED spreader light enclosures

Filled epoxy was applied around the underside of the base to have it better conform to the deck.

 

[Walter P]

Vincent,

Outstanding job. Congrutulations on a good looking and practical improvement.

Walt

 

[eze2bme]

Vincent ... looks great ... just curious ... how/where did you run the cabling/wiring?

 

[Vincentc]

Thanks,
Right now the only cable run is inside the hollow mast, the rest of the cable is coiled up in the storage area of the base. I am going to drill a 2" hole near the stb side of the mast base and in the base of the stb. side flybridge seating area and connect the holes with a length of 2" stainless tubing and run the cables inside that tube.
Regards,