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Crevice corrosion on the mast (Photos 1 and 2) is obvious as it bubbles up between the layer of paint and the aluminum mast. The first step (Photo 3) is removal of all traces of corrosion first with a scraper, then with a wire brush, and finally with 80- and 120-grit sandpaper. Next, etch the surface with an acid solution (Photo 4) and apply primer (Photo 5). Sand the primer layer with 220-grit sandpaper (Photo 6) and spot-paint with a thinned coat followed by a layer of top coat. Hand-sand with 220-grit paper. The final coat is a thinned layer. First spread the paint horizontally but finish with a vertical stroke to prevent curtains (Photos 7 and 8). The finished mast is Photo 9.

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Spiffing up the spars

How to repair corrosion damage on painted aluminum Issue 40 : Jan/Feb 2005 How does the paint look on the painted aluminum of your boat? Is it bubbling up and breaking through the surface? This is the...

Steven Alexander

September 2, 2026

Browsing Tag: Steven Alexander

Spiffing up the spars

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Installing a new engine

A clean look at the “dirty” half dozen

Cozying up your cabin

End the “dinghy dilemma”

Dave Gerr on glass

New swageless fitting shows promise