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I ordered the cap from Sunfish Direct...looks very similar, but diameter was slightly off. I donated the new cap to the club shed in exchange for the old one. I will try to measure it the next time I go to the beach.

Even after sanding, the new cap did not fit. I found a used cap in the club supply shed that fit my 1978 mast perfectly. Just an observation, but the o.d. of the new mast cap was slightly larger than the old mast cap.

My boat is stored at the beach, and we are off to Oman this weekend. I had started sanding the inside of the mast (corrosion) and the outside of the cap, but with 200 grit sandpaper (all I had). I'm going to dremel the outside edge of the cap at home, and try the tappity-tap method. I tried...

Yes, it is cork. I just found elsewhere in the forum that newer sunfish masts have a larger inner diameter than the old ones. So, new mast caps don't fit. Only solution is to laboriously sand down the new cap until it fits. Thank the Lord that I don't have any other hobbies.

I have to resurrect this thread. My mast has no base cap, but I can see the wood insert a couple of inches in. I have a new mast cap, but it is slightly too large to fit. I did some manual sanding but couldn't get it to fit. I looked down the mast and can see what looks like a reinforcement...

No Pics, but JB Weld did the trick. Now with a proper length tiller, a new rudder, and tight connections the boat handles and maintains course so much better. First races for me yesterday resulted in a 3rd place overall finish in the Novice class. I'm totally hooked!:D Thanks gurus!!

Thanks all for the helpful replies. I sail in a hyper-saline bay in the Arabian (Persian) Gulf. The inside of the cheek is heavily pitted/worn as well. I'm trying the JB weld method, but when I go back to the States in December I will bring back a plastic cheek. The boat has been sailing the...

Thanks sailcraftri. I live in Saudi Arabia, and things like JB weld can be hard to find. But find it I did! I'm heading to the garage now to sand and weld. I'll post pics of the results.

I'm replacing my rudder, and I noticed that the aluminum rudder cheek holes are worn out of round. Also slightly corroded. Is it time to replace?