I just finished my last epoxy tango on the boat build by assembling my mast. It all went together fine. I only had enough epoxy to assemble the aft and 2 sides last week so stopped at that point and just clamped and held down those 3 sides with a spacer in the middle where the forward side will eventually go and ordered more epoxy.I planned to install the forward surface today once the additional epoxy shipment showed up. I installed the forward surface and now I have it clamped down to my 16ft work bench. I went back over the assembly to remove any squeeze out. When about 6 feet down from the top of the mast I found an 18 inch split in the forward facing surface running up the middle surface! I don't know when it split, maybe as I tapped it home to the other 3 sides or maybe when I clamped it down but, no matter the reason, the split is there.
I am trying to figure out what to do next. I will just have to let the forward side cure until tomorrow.
Should I:
1. grind maybe a 3 foot area out of the forward surface and scarf a new piece in?
2. cut out the area and scarf another piece in and also a solid filler in the middle of that new piece?
3. try to separate the split a bit and get epoxy in?
4. fiberglass the area that is split maybe?
Looking forward to any and all ideas at this point. I really can't see having to replace the whole mast but, of course that is always an option.
Thanks,
Mike