: Hi Pete,
: Here is the way I made a mast step. I had a set of saw hole cutters I think I
: bought at Walmart for about $6. Since my aluminum mast diameter is 1 1/2
: inches O.D. I used the 1 3/4 inch cutter for my mast to drop inside. This
: leaves 1/16 inch clearance on each side of the mast after the cutter walls
: are subtracted. I ground the teeth off and mounted mine by fiber-glassing
: in place. When the mast is dropped into the step the large radius at the
: bottom centers the mast and keeps it stable with no slop or movement.

: John

Interesting idea. A decent amount of clearance around the mast is always a good idea. Too close a fit and the mast can jam in place.