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Black Panther

Internal mast seal

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If using pourable silicone, first check there are no old rivet holes or other gaps in the mast wiring conduit that the silicone can flow into. Otherwise you’ll fill up the conduit and not be able to replace or draw new wires through it!

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Who stocks pourable silicone? I haven't been able to find anything that will pour and self-level except a Sika product for teak decks that has to be bought in bulk and has a short shelf life!

Edited by ballystick

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When I did a mast on a previous boat I did the balloon trick, poured a thin epoxy slurry (it levels out the balloon top) then teak deck sika product. Epoxy would have done it except that heat/cooling cycles could have eventually broken the seal hence the teak deck stuff, (which was eyewateringly expensive) 

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I did as suggested by Steve Ashley and removed a halyard sheave box near deck level. If you don't have a hole there I imagine cutting one around 50-60-70mm dia should be ok - check with a mast fabricator

Next shaped some flexible foam to approx mast shape and pushed it in through the hole and down say 15mm below sheave hole.

(Flexible foam - might have used the stuff Burnsco sell for seating - not sure.)

Then spread flexible sealant from Sika on top of foam and left to set. This was a few years back so can't remember the name of the sealant but it was not silicone. As Steve mentioned it was thicker than what Sika used to produce so dificult to push around back of cable tube so we still had a slight leak.

Next mod was put in a layer of slightly thickened epoxy on top. Voila no leaks and been there at least 5 years.

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