Ouch! How did you do that?
I think you might have to fill it with an epoxy paste, and then drill the holes where they need to be. You would then grind it back to where the carbon is now, and then add layers of carbon to it, and vacuum it down. You of course are going to have to then reshape it so that the outside diameter still fits your boom.
Great photo for the FUNNY IMAGES thread !
Cameron just invented a new adjustable outhaul system
or perhaps
Drill a couple of holes on the side at 45 deg and fit a slotbox fin.
See you on Wednesday
It looks like a big sail boom. It might be easier/safer to replace the whole broken tube. If its a single pin adjuster, it should pretty easy find a second hand carbon rear-end and adapt it to fit yours.
Fill the gap with pu foam from a can, after setting remove foam and level with inside boom . sand the sides from the part you need to rebuild. cut carbon fiber strips and mix epoxy resin, rebuild from the foam up layering the wetted out strips, vaccuum, cure, sand , drill , surf.
walk in the park
Replace it, I doubt any kind of repair would return it to original strength, they aren't supposed to last forever, nothing is for that matter.
Make up a 'c' section pipe long enough to bridge across damage to slip inside
roughen up interior and glue inside
fill and fair fair the exterior void
cheers jeff
it can be fixed with some carbon cloth and resin ....
i had one like that ,,,not as bad ...but i had 3 sail all in 203 205& 200.
I drilled a few holes and pop riveted it ..and just use it for them ..its a stiff carbon boom now set for my 7.0.,6,3 and 6.5 .
i hope my harness lines last for a while ...please note i do have other booms .
Cammd, i dig the pvc use . Doesnt rust, doesnt corrode, easy to work with.Im a sparky n use pvc electrical components to fix n make all kinds of odd things. Knife scabbards,berley bucket n muncher, mast spacer/protector, rodholders, containers to hold screws n bits.Endless really..Just criss cross score the pvc surface with a knife tip. So the epoxy has some kind of 'key' to the conduit surface. I used 40mm md conduit with bamboo jammed inside to make up a kids rig mast. 18months n still going strong.
Just put a stainless hose clamp around the tail and tighten it up when the boom is set at the correct length and use it that way until you can afford/want (assumption) to buy a new boom.
Carbon covered conduit inserted and now glued in with west system g flex.
My question is should I enlarge the section for repair by making it wider than the holes that will be re drilled. Would that make the repair stronger
I liked the idea of turning the boom over a drilling only required holes, having inserted something to stop the damaged section collapsing. I reckon the sleeve will move for sure if the attachment is to it. Having said that, I've had no experience with this sort of repair.
I combine all methods:
Fill it with foam, sand out then lay up carbon and resin. Err on the side of more laminate thickness than the factory laid up as yours won't be as strong.
No need to vac, really tight taping will do.
Then flip and drill other side
I like your idea of the conduit with carbon so far, but at first glance I say DON'T laminate with g-flex its an adhesive not a laminating resin. They say "can be used" so to me thats a hmmmm
Yes they do go all the way in.
I wonder if I didn't engage them correctly at one time or maybe the previous clips caused some damage when they got old. Usually the pins come loose or the clip cracks and you keep using it until the new ones are obtained. I did the rb words last year with gaffa tape holding it all together causeci didnt have new clips.
I keep spares on hand now
Just buy a new boom, every little creek, crack, or slip that you hear while using it will make you worry, taking your attention away from having worry free sailing. "What was that? I may have to go in and check my boom, I hope I make it in".
Not worth it, believe me I've tried stuff like that. Back in the late 80's I had a mast that would make these cracking sounds whenever I rotated the booms up to rigging level (tie on booms), so I shoved a piece of broken mast up inside the weakened mast to where the booms attached, with glue. It stopped the cracking noises while rigging, but I never trusted it, and got rid of it, not to mention the added weight.
It was not worry free sailing.
Also, what caused that kind of unusual wear? Something did, has that been addressed? Or are you just patching up something that shouldn't have happened in the first place? If you aren't sure what caused it, you're just wasting time.
I'm done.
Since were discussing boom repairs I have an easier one I need advice on.
the pop rivet attaching outhaul pulleys at the tail of the boom has corroded away so it's now only barely holding on relying on the shape of the assembly. It also looks like the pop rivet hole in the carbon has elongated a little.
whats the best way to fix this. Should I use an oversized pop rivet or fill it and use a screw....any suggestion welcome.