That does sound like a challenging project Matt. Interesting that your mast step bent - my casting cracked in two around the keel bolt. However I don't have the stringer setup you do - it looks like it is just solid fiberglass with filler under the mast on my 34.
Not the same part but I just designed a replacement mast step for my C&C 34 and had it machined from 6061 T6 aluminum by xometry. Photo of finished part: https://photos.app.goo.gl/8GVyzAsBASdW8MuP7 It was about $700 including shipping (made in the US) which wasn't too bad as a one-off. The design is here in on-shape if anyone wants to copy it: https://cad.onshape.com/documents/06778e11eadafc92b785b709/w/b7bc0fda88594aa1bd5a947b/e/dbcde4431b1a8f7be673194e It is based closely on the original casting dimensions but designed so that it will not collect water anywhere. I figure out of 6061 it will be stronger than the original casting (which had cracked) and should last another 40+ years if I bed it properly with filled epoxy so that it doesn't have large bending loads applied. Nathan ~~~ Nathan Post S/V Wisper 1981 C&C34 KCB Portland ME
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