Independent guide: Coating systems vary. Follow the paint manufacturer's system for aluminium spars.

Quick answer

A mast refinish is more than cosmetic. On an aluminium mast, failing paint usually signals corrosion underneath, especially around stainless fittings. A proper job needs the mast out, every fitting removed, corrosion cleaned out and treated, the surface prepared and coated in a system designed for aluminium, and fittings refitted with isolating compound and new fasteners.

Signs a mast needs refinishing

  • bubbling or lifting paint around fittings
  • white powder at fasteners
  • chalky, faded paint losing adhesion
  • anodising worn through to bare aluminium
  • previous touch-ups failing

The process

  1. Unstep the mast — see mast stepping.
  2. Remove all fittings, recording positions.
  3. Strip failed coatings and clean out corrosion pits.
  4. Assess any significant corrosion with a rigger — see mast repairs.
  5. Prime and paint using a system suitable for aluminium in a marine environment.
  6. Refit fittings with isolating compound and new fasteners.
  7. Restep, re-rig and tune.

Painting and re-rigging together

A refinish is an ideal time to re-rig, rewire and service the furler, because the mast is out and stripped anyway. Combining them avoids a second crane and yard bill.

Boats that benefit most

  • Older painted masts on 1980s–2000s production boats
  • Tropical boats in Queensland and the Northern Territory, where heat and UV break down coatings faster
  • Classic yachts with varnished timber spars, which need their own maintenance regime

Frequently asked questions

Why is the paint bubbling on my mast?

Bubbling paint on an aluminium mast is usually corrosion lifting the paint from underneath, most often around stainless fittings and fasteners where galvanic corrosion occurs. It should be investigated rather than painted over, because the corrosion continues beneath the new paint.

Can a mast be painted with it stepped?

Touch-ups can be done aloft, but a proper refinish needs the mast out, fittings removed and the surface prepared along its length. Painting in place rarely achieves good adhesion or corrosion treatment around fittings.