This is the mast that we made for a classic Pathfinder design by John Welsford . We also made the boom and the gaff out of carbon.
We started from the standard geometrical specifications found in the plans. From there we calculated the stiffness (Second Moment of Area) of the mast and recalculated this into the material parameters of Carbon/Epoxy; the same for the gaff and the boom.
This resulted in a lighter, stiffer and stronger mast than the original alu one ...
We used a male mold, heat-shrink tape and carbon pre-pregs (90 % uni-directional). The spars were cured under vacuum at 130 ºC (266 ºF). In this case the customer finished the spars with a two linear PU varnish from Stoppani. We can also provide spray finished spars in any color ...