NowhereMan:
I've been trying to put together a second AI from a Hobie Adventure (older version of Revo 16), and it's complete, except for the mast. The official Hobie mast is over $800, and I don't think it is even possible to get the pre-2015 version. So, I decided to try a windsurfer mast.
I found a used 460cm (15' 1") 90% carbon mast for $200 (no shipping, no tax), so I figured it's worth a try. The mast is exactly the same length as the Hobie mast, it's about 1mm narrower at the base, 2mm narrower at the top, the thickness at the center coupler is 1/16" (Hobie is 3/32"), and it weighs 3.86lbs (about 1/2 the weight of the Hobie). I did a few flex testing experiments, and as near as I can tell, the windsurfer and Hobie masts are virtually identical in that respect.
I bought the Hobie mast base and collar and attached them to the windsurfer mast (rivets for base, G-flex for the collar). The mast top piece seems to be currently unavailable, and since it fits inside the mast, it would not work without major modifications anyway. So, I made a little dohickey out of a solid piece of 1.5x1.5x3 inch piece of starboard plastic (not easy without a lathe...). That slips into the top of the mast. I've also got a mast topper that I use, which is the secret ingredient that makes it possible to fly a second sail (jib/genoa or spinnaker), and I figured out how to add that to the top. That was actually a bit tricky, as the sail is not a standard Hobie sail--it's from Intensity Sails, and was super-cheap (like $200, although, unfortunately, they don't sell AI/TI sails anymore). The non-Hobie sail has a narrower sleeve, so I could not slip 1.25" PVC pipe through it, and had to use some narrower (but, supposedly, extra-strong) below-sink PVC instead.
The only things remaining are to spray paint the mast-topper tube, and put one bolt thru to connect to the top of the sail, which should be done in a day or 2.
I might try to replace the mast-topping tube with aluminum tubing. I'd also like to redo that white starboard plastic piece in aluminum, but I don't have a metal lathe, and that would probably be beyond my limited angle-grinding skills.
The lighter weight aloft will be great, but a broken mast would certainly be no fun. A jib definitely puts some extra stress on the mast too.
I was hoping to test it out this weekend, but it looks like the wind will be practically zilch after Wednesday, so I might have to wait a bit to see if it'll hold up. In any case, I still need to find some battens, so if anybody knows where I can get 3/16" fiberglass rods in 10' lengths locally, LMK. I can find them online, but shipping is pricey.
A bunch of pictures...
NowhereMan:
These pictures show the windsurfer mast next to my current Hobie mast...
NowhereMan:
Tap Plastic has 3/16" fiberglass rods, but only in 6' lengths. I used short section of brass tubing to join pieces together to make get the proper length for the battens.
It's now ready to sail--just waiting for some decent wind to test it out. One thing I am sure of is that I'll feel very patriotic sailing this boat...
fishbushing:
That looks really nice!
AlsHobieOutback:
It will be really cool to see her rigged and try to keep up with you on the water :smt003. I've could really use a mast adapter, I'd like to have something like a 3ft pole I can drop in the mast hole. I envision stretching ridge line tarp from front to rear for the sunny and rainy days.