Chuck:

Since I assume you were talking about the Main Mast step, I thought I would
start a new thread. I was going to get mine done by Metalmast ( I believe
the price was $300 – 350 when I asked last year), but thought I would check
at my local welding shop for a cost comparison. They made me an aluminum
copy of the old galvanized steel one for $110. It was made out of 1/4″
aluminum and it fit well into the mast.

However, being out of aluminum, it of course feels very light and I started
to have doubts if it is strong enough. Probably just my mind playing tricks
on me, since I assume most of the forces are right along the weld seam on
the bottom. If anyone else has had theirs re-made in aluminum, I would be
interested in hearing what thickness was used. I will also need to check
what grade of aluminum was used??

I will probably beef it up just to be safe by using a couple strips of 2″ x
2″ angle laid athwartships in place of the square washers that were
originally used under the lag bolts. I will then run a couple of bolts just
either side of the mast running fore /aft. This is probably be overkill. but
back-up support will never hurt and shouldn’t cost too much.

Paul

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