The top of the mainmast had a 'Mark 1' mast band. The fore-stay, shrouds and halyard were all attached to a stainless steel continuous welded ring held in place by a galvanised staple and a large brass split pin through a hole in the mast button. There was no way of removing shrouds or fore stay without cutting the ring. Note how the shrouds have gouged into the mast shoulders.

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The ring was removed by cutting through it with a hacksaw and the shrouds, halyard and fore stay removed. The wood at the top of the mast had been badly damaged by the action of the shrouds pulling unevenly on the ring. The mast button is of a much smaller diameter than the new mast band. Cutting off the top of the mast was not an option as then it would have been too short!! Filling seemed to be the best solution.

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First the stained and decayed wood was sanded away using a sanding block (80 grade), a circular rasp and various needle files. This left sound wood to form a sound bond with the Epoxy resin and adhesive filler.

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The bare wood was coated with West Epoxy Resin 105 using standard 205 hardener and then immediately built up with a stiff mixture of resin 105 plus high density filler 404. This was then left to cure for 24 hours

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The filler was sanded to shape and a plywood template (bottom of picture) used to mark the position for a new stainless steel mast band. A hacksaw was used to cut a platform for the new mast band.

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Plan and side views of the stainless mast band which was used to replace the original stainless steel ring.

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The new mast band was placed in position with care taken to ensure that the fore stay and shroud plates were correctly positioned relative to the position of the mast in the boat. This was achieved by attaching a line to the down-haul cleat (positioned on the aft side of the mast) and running it to the screw hole on the aft side of the mast band. Sighting along the line allowed the mast band to be lined up and temporarily fastened with a self-tapping screw into the mast button.

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The gap between the mast button and the inside of the stainless steel mast band was then filled with West Epoxy Resin 105 using standard 205 hardener plus high density filler 404. This glued the button to the mast band as well as effectively filling the gap. The whole was then left to cure for 24 hours. The excess filler was then sanded away to achieve a reasonably smooth finish.

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Originally the main halyard sheave was attached to the stainless steel ring at the top of the mast. With the replacement of the ring by the mast band the simplest way of attaching the sheave is for it to share the same shackle as either the port or starboard mast band shroud attachment points (or tangs). In the adjacent photograph, the sheave is shown attached to the port tang of the mast band (the forestay is on the left, attached to the front tang of the mast band).

It should be noted that on currently produced Lugger masts a mainsail halyard sheave is not attached to the mast band at all. Instead a slot is cut through the mast just below the mast band to accommodate a pulley for the mainsail halyard. The advantage of this is that, when the mainsail is hoisted, the gaff is pulled closer to the mast. It would be possible, with care, to retro fit a pulley by cutting a slot and drilling a hole for a stainless bolt to act as an axle. This may be featured as a future project. In the meantime, the sheave attached to the mast band is equally functional although care is needed when rigging to ensure that the sheave is fastened on the inside of the associated shroud.

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