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Date Posted: - Thursday - 06/23/05 - 6:04pm
Author: Wes
Subject: Re: mast varnish
In reply to: Robyn 's message, "mast varnish" on - Tuesday - 06/ 7/05 - 9:52pm

Robyn, I completely restored a 40 foot Sitka Spruce mast off a 1934 racing sloop a couple years ago. It should be noted you should use whats called a "penetrating epoxy" as opposed to the standard epoxy you find on the shelf for fiberglass work. Josh hit the nail on the head "special coatings", don't confuse it with standard epoxy.

It was suggested to me years ago to use "Smiths Clear Penetrating Epoxy Sealer, also known as CPES" (West system also has a version of an epoxy sealer but I have no experience with it) prior to varnishing. The stuff ain't cheap but it works like a champ. It is much less viscous than epoxy and actually goes into/bonds with the wood fiber structure as opposed to just being an external coating (each subsequent application sealer goes deeper into the wood, unlike epoxy which will build up on the outside of the last application.) CPES bonds to the internal structure of the wood much better and allows the varnish to actually bond directly to wood/CPES substrate, again as opposed to outside of an epoxy coating, preventing flaking, crazing, cracking, important on a mast under variable flexing situations. This translates into easier maintenance and upkeep as long as the schedule recommended by Bristol is maintained, you never have to sand your masts again! Don't use old varnish, it may not be UV rated, and it tends to loose its ability to resist UV after sitting around for long periods, the "microscopic UV flakes/specks" if you will, deteriorate and never mix well again. "Cheap and or free" I have found translates into more sanding and more applications/work later down the road.

The problem with straight forward epoxy is assuring a sucure bond (it will only bond a fraction of the depth into the wood structure that a penetrating epoxy will) over every square millimeter of the mast so when the mast flexes it doesn't crack and worse yet, flake off (This takes precise environmental control, and super accurate thining of the epoxy). CPES claims to compensate for and allow for this flex with its proprietary chemistry and in our experience works marvelously. (Really, I don't sell the product just enjoy the results) We applied 12 coats with minimal sanding of "Bristol Varnish Traditional amber" after 4 coats of CPES, and when it was completed it compared to a piece of fine furniture.

You can go to www.star-distributing.com for more info or just type in the above product name to search for the company's website. The Bristol/CPES combo is an upfront expense, but who wants to completely revarnish their mast every year or two or three?! For more intense sunny climates take some advice that was given to us in regards to our Mariner and paint the masts white, much less of a nuisance and way easier/cheaper to maintain. The Bristol/CPES combo will certainly accomplish your weather objectives.

A note on Bristol varnish, make ABSOLUTELY sure the wood is clean, otherwise small bubbles/pock marks from oils or other residue makes the work 10 times harder to accomplish. We have found Bristol varnish is completely intolerant of any residual oils and especially tack rags (as no matter how light you wipe, enevitably some microscopic residue is left behind and the results are demoralizing) so beware.

A final note on penetrating epoxies, they usually come with very high VOC ratings and the fumes are toxic, take special care in your application environment.

I believe nothing compares to a brilliantly varnished pair of masts! I have restored allot of wood with the CPES/Bristol combo and it works like a champ, eventhough the pocket book is a little lighter!
Good luck
WES

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