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Removal of a failed mast step on a Panda 40 requires cutting out the original fiberglass-encapsulated wood, which had suffered significant compression and deformation.0:35 The mast shoe had created a 1/8-inch depression in the step, likely caused by water intrusion through the lag bolt holes that rotted the underlying wood.2:50 After removing the old step with a Sawzall, the crew inspected the underlying cross beam and found it structurally sound and dry, eliminating the need for deeper repairs near the keel.8:04 The replacement step consists of 2 1/4-inch thick marine plywood, reinforced with side braces and fully encapsulated in West System epoxy.10:00 To ensure a strong bond for the new tabbing, the crew sanded the surrounding bilge paint down to the hull laminate.9:38 The new assembly was dry-fitted to the cross beam before final epoxy coating and glassing.11:03 Over-drilling and epoxy-filling the new lag bolt locations will prevent future water ingress.6:06

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