This is the 'How To' portion of the small sail adapter for the 2007 AI. There were some changes for the '08 AI and Stringy
has posted an updated How-to here:
Regardless of what version you have, you can see the description and operation here:
The finished product will look something like this:
I bought all the parts through Hobie or Home Depot. Here's what you need (reference picture below):
Hobie parts (all in black):
79512 mast collar (top left)
84550001 mast base, kayak (tube, right side)
79511001 mast base/pin (bottom middle)
From Home Depot (or any PVC supplier) -- note - Brands vary in size and style. These are made by DURA USA. All sizes are inches unless noted. Some trimming will be required. Best to take the mast collar along to verify fit:
1 ea -- 1 1/2 slip/slip coupler (lower middle)
2 ea -- 1 1/2 x 1 1/4 slip adapter (middle, attached to 1 1/4" pipe top and bottom)
1 ea -- 1 1/2 x 1 slip adapter (top right)
1 ea -- 1 1/4" PVC pipe x 7"
PVC primer and glue
epoxy -- find one that works with PE like 3M Scotch Weld DP 8010
one sheet, medium sandpaper
small stainless "S" hook
black paint/primer to suit
All parts should be fitted dry before any gluing is done. This next pic shows pre-fitting the 1 1/2 x 1 1/4 adapter inside the mast collar. The lip here may need some sanding. Aim for a snug fit.
The 1 1/2 x 1 adapter will fit into the top of the mast collar. It may not need trimming.
The kayak (small sail) mast base fits into this adapter. The inside bottom lip of the adapter will need some trimming to accommodate the tube. I used an exacto knife. If you want a flush mount (as shown), you will sand down the tube top flange. This is not necessary though. When fitted, it should look something like this (note tail of mast base protruding through bottom of 1 1/4 tube):
Once the pre-fitting is complete, glue the 1 1/4 pipe to the trimmed 1 1/2 x 1 1/4 adapter. Epoxy the two adapters back to back, using any available tape to align them until set, as shown below:
With epoxy, glue the 1 1/2 slip connector to the mast base/pin; glue the other (untrimmed) 1 1/2 x 1/1/4 adapter to the other end of the connector. Epoxy the preassembled insert into the mast collar. DO NOT
GLUE THE 1 1/4 PIPE TO THE BOTTOM ASSEMBLY AT THIS TIME.
Before continuing, you'll need to measure and trim the 7" tube length to replicate the correct height of your original mast base. Probably less than 1/4" trim (if any) will be necessary. Better to be too long than too short. Test fit this to your boat to verify before gluing! You will then need to carefully trim the small sail tube so that it seats in the bottom of the mast base/pin. Double check these parts dry until you're satisfied you have it right.
Glue the 1 1/4 pipe (with top assembly) to the bottom assembly. Insert and glue the small sail tube so that it is glued at the base and top. When done, it should look like this:
Bevel this lower shoulder as shown to ease extraction of the adapter:
Modify your "S" hook to permanently fit your bungee. It will hook to your adapter as shown:
Prime and paint to suit.
Revision -- I originally used JP Weld epoxy. Unfortunately it eventually failed. You may need a glue that can bond with PE. The only one I know of is now listed on the materials list above. Here's a link that gives a little more info on glues: http://www.hobiecat.com/community/viewt ... b166a57a27
Perhaps DuPont has an equivalent? Good luck!