Sheared screws in mast step

   The mast step in my Flying Fifteen has worked loose. When I tried to remove it, two of the forward fixing screws sheared off rather than screwed out, creating even more movement, as it is now held in by just two screws aft.
Would anyone have any tips for removing the screw stubs left within the deck, doing the least damage possible? I'm thinking drill out and fill with epoxy, but wondering if there are better methods.
Thanks in advance!

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Wobble Send Private Message Find Member's Posts Groupie Joined: 26 Jul 10 Online Status: Offline Posts: 44	Post Options Post Reply Quote Wobble Report Post Quote Reply Topic: Sheared screws in mast step Posted: 15 Jul 19 at 11:40am
	The mast step in my Flying Fifteen has worked loose. When I tried to remove it, two of the forward fixing screws sheared off rather than screwed out, creating even more movement, as it is now held in by just two screws aft. Would anyone have any tips for removing the screw stubs left within the deck, doing the least damage possible? I'm thinking drill out and fill with epoxy, but wondering if there are better methods. Thanks in advance!

Sam.Spoons Send Private Message Find Member's Posts Really should get out more Joined: 07 Mar 12 Location: Manchester UK Online Status: Offline Posts: 3393	Post Options Post Reply Quote Sam.Spoons Report Post Quote Reply Posted: 15 Jul 19 at 12:02pm
	The broken screws will be brass, bronze or stainless steel and much harder than the wood or GRP they are fixed into. This will make them incredibly difficult to drill out as the drill will constantly try to wander into the surrounding material. Try heating the screws with a large soldering iron before gripping the end with a mole grip (same for the remaining two, heat before trying to remove). It'll leave a divot around the top of the screw hole but might leave the most of the depth still functional. Edited by Sam.Spoons - 15 Jul 19 at 12:03pm
	Spice 346 "Flat Broke" Blaze 671 "supersonic soap dish"

Wobble Send Private Message Find Member's Posts Groupie Joined: 26 Jul 10 Online Status: Offline Posts: 44	Post Options Post Reply Quote Wobble Report Post Quote Reply Posted: 15 Jul 19 at 12:58pm
	Thanks for your very quick response Sam. The problem is that the screws (they look like low-grade stainless, and much lighter than I would have expected) are broken beneath the surface, so I have no way to grip them externally. The other two have already been removed and replaced with new stainless screws, up one size.

Sam.Spoons Send Private Message Find Member's Posts Really should get out more Joined: 07 Mar 12 Location: Manchester UK Online Status: Offline Posts: 3393	Post Options Post Reply Quote Sam.Spoons Report Post Quote Reply Posted: 15 Jul 19 at 1:11pm
	Tis a tricky one, and it's a while since I had to do it. Can you get a drummer* and put a slot in the top then apply heat? What's probably happened is that the screws were coated in varnish or something when they were fitted and heat will soften that, also expansion may break the grip the wood has on them. Failing all else drilling them will probably result in a much larger hole which you could fill with epoxy and microfibres as you originally suggested. Good luck. Edit :- * Yup, Dremmel obviously though I know a drummer who might do it........... Edited by Sam.Spoons - 15 Jul 19 at 5:13pm
	Spice 346 "Flat Broke" Blaze 671 "supersonic soap dish"

Wobble Send Private Message Find Member's Posts Groupie Joined: 26 Jul 10 Online Status: Offline Posts: 44	Post Options Post Reply Quote Wobble Report Post Quote Reply Posted: 15 Jul 19 at 2:45pm
	What's a drummer? Apart from that, looks like a drill and fill!

Noah Send Private Message Find Member's Posts Really should get out more Joined: 29 Dec 04 Location: United Kingdom Online Status: Offline Posts: 611	Post Options Post Reply Quote Noah Report Post Quote Reply Posted: 15 Jul 19 at 3:34pm
	I think drummer may be an auto-correct from Dremel...
	Nick D-Zero 316

didlydon Send Private Message Find Member's Posts Far too distracted from work Joined: 15 Oct 08 Location: Margate England Online Status: Offline Posts: 280	Post Options Post Reply Quote didlydon Report Post Quote Reply Posted: 16 Jul 19 at 10:15am
	If you can get in there to use a Dremel, use a small diamond burr to "spot" it then gradually enlarge the burr keeping it on course till its gone. Patience & perseverance needed here!
	Vareo 365

Wobble Send Private Message Find Member's Posts Groupie Joined: 26 Jul 10 Online Status: Offline Posts: 44	Post Options Post Reply Quote Wobble Report Post Quote Reply Posted: 16 Jul 19 at 11:33am
	Thanks Sam and didlydon both. All a bit scary. I'm thinking of taking a swerve and drilling two new holes in the mast step. It'll be a bit weaker, but the attachment to the boat a bit stronger, I reckon.

jharvey Send Private Message Find Member's Posts Newbie Joined: 11 Sep 12 Location: Bristol Online Status: Offline Posts: 20	Post Options Post Reply Quote jharvey Report Post Quote Reply Posted: 16 Jul 19 at 5:27pm
	Is there any room to move the mast step forwards or backwards an inch and have 4 new holes?

Wobble Send Private Message Find Member's Posts Groupie Joined: 26 Jul 10 Online Status: Offline Posts: 44	Post Options Post Reply Quote Wobble Report Post Quote Reply Posted: 16 Jul 19 at 6:11pm
	Good idea, thanks! I'll check to see if there's room for manoeuvre.