This is the mast base of my 1979 Hunter 33. The mast is deck stepped and sits on an aluminum flange which has already been removed in this picture. (You will see it later)

I was going to run mast wires through an exisitng hole in the deck (the large dark spot at the bottom of the picture) but found the core to be soaked.

I tried to use a bent nail in a drill to clear out the wet wood but there was too much of it. I decided to cut out the step.

Before Repair

I used a cutting wheel in an electric drill to cut out the top layer of glass and expose the core.

It is 1/2 plywood.

Wet Core

I used 40 grit sandpaper on a 5 pad chucked in my drill to clean up the area after using a chisel to get most of the wood up.

Cleaned out

I replaced the plywood with solid oak, 1/2 thick. I jammed the wood under the lip and filled all voids (a very small amount) with cloth, chopped glass and resin.

New base

This picture shows the base built up with layers of mat and cloth. I built it up slightly above the surrounding edge and then sanded it flat.

I coated the top with primer and installed the flange in a bed of 4200. The bolts were snugged until it set and then tightened down.

I touched up the cosmetics of the job using epoxy putty.

Built up and flange installed

I have one coat of paint on the base at this point. Ill be adding two more. Wish the rest of the deck looked this good.

Products Used:
West System epoxy,
Glass cloth and mat,
Epoxy putty,
Brightside paint*.

*Left over from my mast. Next year I will redo the deck with epoxy paint.

New Base