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Maststep

• You will need:
  
  
  • 2 pcs 1" sq. tubing or 1-1/2" angle iron 8" long (I prefer the angle iron)
    
  • 2 pcs 1-1/4" angle iron 6-1/4" long
    
  • 2 pcs of chain link
  • 4 5/16" bolts 1-1/2" long, washers and nylon locking nuts
  • 1 pc of 2" O.D. tubing with 0.12" (1/8") wall, 7" long. Make sure this tubing is exactly this size. If a different diameter is used, it may bind with the mast. This is structural tubing, not pipe, so it may be a little hard to locate. If you have trouble finding a piece, email me, I may be able to send you a chunk of it.

In order to mount the maststep at the proper angle, you will need to have the front forks installed. You do not need to have any of the wheels mounted, as the angles will all be the same if the front forks and rear axle are sitting on the floor. A floor jack and a piece of plywood, around 18" square, will be helpful.

Clamp and weld the 2 8" pcs. of 1" square tubing or angle iron to the inside of the side tubes. Use the floor jack and plywood to hold the square tubing.

Drill 5/16" holes 1" from each end and 1/2" from the edge of both pieces of 6-1/2" angle iron.

Clamp the 2 angle iron pieces to the square tubing.

Drill holes in the square tubing, and bolt angle iron.

Weld a large washer to one end of the 2" tubing.

Place the 2" tubing between the angle iron pieces. Use a level to ensure that the tube is vertical, both fore and aft, and side to side. If you have 2 levels it is even easier. Clamp or brace in place somehow, then tack weld upright tube to angle iron. Magnetic angle welding clamps are a huge help in holding the tube in place.

Unbolt the angle iron/tubing assembly from the frame. Weld a good bead between the tube and the angle iron all around.

Remount the maststep. Weld cut chain links to the back side. This is where you will hook the sheet block.

When rigging up the sail, a piece of pipe will slip into the maststep. This will internally support the mast.

 

Questions? Comments? Suggestions?