How to extend a mast with an internal track

Paul Croote (Dog 2645 Cheese Before Bedtime) has a very neat mast from Tropical Engineering in Cowes. This mast has served Cheese for many years, but to upgrade to 2005 rules it needs to be extended. Mast extensions are not eaxactly an overnight job, but they are not difficult to do. What makes this extension project special is that the mast has an internal carbon track. This is what he did:

1. Tapered about 100mm of the top of the mast and shaped some low density foam.
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2. Here it is again from the end. Note the taper continues.
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3. On go about 4 layers of 200g Uni's. The individual bits of cloth are trapezoidal to avoid a stress riser.
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4. This is consolidated with some polythene.
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5. Here the Uni's have gone off.
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6. The slot for the track is cut out after the foam blank is removed. You can see the top of the old track within.
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7. The new track tube is glued in place (carefully)
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8. Some weave is put round the whole thing to improve looks and hoop stiffness
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9. After finishing this mast looks like a fine job!
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Would you like to learn the skills to do this? The Class Association runs informal weekend get togethers where new members can learn from the experts. There's one coming up, so why not will_lee us?