Sam Holmes Sailing · video

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Sam Holmes installs four internal halyard exits in a mast by 3D printing plastic templates to guide the cutouts.Watch He drills and taps holes for the exit boxes, staggering their positions to maintain mast structural integrity.Watch To prevent galvanic corrosion between the stainless steel hardware and the aluminum mast, he applies Lanacote, noting its consistency is softer and stickier than Tefgel.3:56 After fishing the jib, main, and spinnaker halyards through the mast using a messenger line, he removes external halyard hooks that previously snagged on rigging.3:08 He also repairs a bent whisker pole by cutting out the damaged section, rounding the tube in a vise, and securing the end fitting with machine screws instead of rivets.8:34 This modification shortens the pole by approximately two feet.8:44 Finally, he replaces a corroded masthead fitting with a thicker aluminum plate to accommodate a VHF antenna, navigation light, and camera mount.8:02

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