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Spreaders
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Installing Spreader Bracket Compression Spacer

Click On Drawings To Enlarge
When installing the "new style" spreader brackets, you must insert a compression tube inside the mast to prevent the cross-bolt and spreaders from crushing the mast

To install the spacer, I use two 8-foot 1 x 2s overlapped about 2 feet and taped together with duct tape. Others have described using water hose with a slot in the end.

To prevent the tape from sticking to the spacer, wrap a piece of tape around the end of the 1 x 2 and spacer with the sticky side out. A wrap around the 1 x 2 will hold it in place. A second layer of tape around the end of the 1 x 2 and spacer with stick side in keeps the tape from sticking to anything inside of the mast while inserting the spacer.

 Several wraps around the pole secure the tape to the 1 x 2. A little "nick" in edge the tape between the end of the 1 x 2 and spacer will make it easier to remove the 1 x 2s and tape later.

Lay the 1 x 2s and spacer along the outside of the mast and align the spacer with the cross-bolt hole in the mast. Mark the 1 x 2s even with the base of the mast a so you know when the spacer has been inserted the correct distance

Make sure there are no obstructions in the mast (I have not had to remove any of the hardware) and carefully insert the spacer and 1 x 2s from the base of the mast until the mark aligns with the mast base.

Hopefully, you will be able to see the spacer trough the bolt hole in the side of the mast. If not pull the spacer out a little and then push it back in.

Next use an ice pick, awl, Phillips screwdriver or other tapered item to line up the spacer with the hole. You may have to alternate working from one side of the mast to the other if the spacer cocks and binds while aligning it. Once the spacer is aligned, bolt temporarily insert the bolt through the mast and install a nut finger tight to prevent it from falling out. Go to the base of the mast and "twist" the 1 x 2s to tear the tape and then remove them from the mast.

Don't know about the new "square" cross-section masts, but the old-style "oval" masts have fairly thin walls compared to other sailboats I've worked on. If you were to drill a hole large enough for the spacer to be slipped in, the mast would be much more easily crushed by the spreaders attempting to "bend" up/down/fore/aft. The drawing is exaggerated to make it clearer to see.

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