A Goose Neck is a critical connection point joining a Sailboat's boom to it's mast ... mine is made of either cast Aluminum or some other kind of Cast Alloy (unknown) ... at issue: bushings that were intended to keep the Pivot Points from wearing out have disentigrated (upper and lower Pin extrusions) ... so ... the bottom Pin extrusion which should be .5" circle (Diameter) is now an oval with a minimum diam of 3.45", and a max diam of 4.85" ... basically the top half of the Pin's original Circle has been worn away.

This part is no longer available from the Vessel's Vendor. To replace this goose neck with some other part would require replacing both the upper and lower mast pivot points, the goose neck, and worst of all, finding a way to adapt the boom to the new goose neck hardware ... all very custom parts.

So, for now, looking to find a way to continue using the existing Goose Neck, by first replace the bushings, and then find a way to repair the worn extruded Pin on the goose neck ... here are some options I am considering

1) complete re manufacture of cast Goose Neck (expecting this could be huge $)

2) attempt to weld some material to the pin (as the cast material is unknown, very concerned that heat from any welding could permanently damage the part)

3) cut the Pin Flush then drill a 1/2" hole in to the part to accept a 1" x 1/2" Diameter Aluminum or Stainless Rod (as the part is only .7" wide very concerned that with .1" wall thickness after drilling, any stress/shock to the pin may result in fracturing the part)

4) following a similar line on #3, the rod could be threaded 3/8" instead of 1/2" providing more wall thickness (requiring a special rod 1" long with .5" at .5" diam and .5" at 3/8" threaded ... again $ involved for custom work)

5) today I was investigating the possibility of leaving the part as is, and building up the missing material with some type of epoxy and or metal filler ( there are so many products out on the market it is hard to know if any of them would do the job ... needing to fill about .5" length by .165" of material ... the bond must be able to sustain -30 to +40, be Water Proof, shock Proof (when a boom whips across from once side of the boat to the other there can be a huge amount of force exerted on the Goose Neck) Thinking I could cut up sewing needles and embed them in to the existing pin to strengthen the bonding surface

6) Other Ideas?

Was hoping the combined expertise of professional metal workers would be able to advise the best way forward so I don't ruin this critical part

Thanks in advance for your time


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