Problem with shroud attachment

[Jim Fulton]

I'm overhauling the mast on my 1975 Bristol 34: removing and reinstalling all of the fittings using Tef-Gel and UHMW tape, running new electrical wiring, etc. I am almost finished with the mechanical work, and I have run into a significant problem with the fitting that connects one of the upper shrouds to the mast. Each shroud is fastened to one of these fittings with a clevis pin. The fittings are attached to the mast with a 1/2" bolt that goes through the mast. This bolt appears to take the load from the shrouds. In addition, each of the fittings is further fastened to the mast by four 5/16" screws. The only function the screws appear to perform is to keep the fitting in position. The problem is that the threads in one of the screw holes have been weakened, probably by corrosion, to the point that a screw will go into the hole, but it cannot be snugged down tight.

I see two alternatives: One is to ream out the holes in the fitting and the mast, and to replace the one 5/16" screw with a 3/8" screw. The other is to do nothing. Presently, the 5/16" screw holds in the hole, but I can't tighten it enough to compress the lock washer. However, any load on that screw is in shear, so nothing will be working to pull it out. On the other hand, I don't like the idea of a more-or-less loose screw at the top of the mast.

My inclination is to go with the 3/8" screw. Does anyone have any other ideas?

Jim Fulton