Reversing Entropy · video

What this video covers

Fabricating custom mast steps requires 25mm-wide, 5mm-thick aluminium stock to ensure structural integrity and eliminate the need for maintenance-heavy, noise-prone padding.1:59 To prevent halyards and lines from snagging, the top corners of each 450mm-long blank must be rounded using a CNC machine or sander.5:22 Proper bending technique is critical; sharp-angle bends created in a standard vice significantly weaken the material and lead to premature failure under load.10:13 A gradual, rounded bend maintains the structural strength of the aluminium.7:42 The final design uses a tripod fastener configuration—one 6mm hole at the top and two 5mm holes at the base—to provide lateral stability and minimise the number of penetrations in the mast.12:36 While Monel rivets are preferred to prevent galvanic corrosion between the aluminium step and the mast, standard pop rivets serve as a functional alternative.13:45 Each finished step weighs 149 grams.14:14 Using thick aluminium stock and rounded edges prevents both structural fatigue and line-snagging hazards.

More from Reversing Entropy

ePropulsion eLite Review: I Paid Full price.Jul 2026I Turned a $12,000 Spectra Into a $500 Watermaker.Jun 2026I Created This Sailing Block. You Found a Secret Feature!May 2026Had to Reinvent the Sailing Block (To Replace Them All)Feb 2026

From Reversing Entropy — see the channel’s boat, crew, and every analysed video.

The Sailing Directory Newsletter

One email with the fleet's best finds — the moments, boats, and stories worth your watch time. Enter your own address to get your own copy.