Ok, If you must design a new boat. Why would you start by developing a mast base that has poor repeatability in the home build arena. Glue seems like a bad idea. If the boat remains a take apart as discussed then why not sleeve your pod(mast base). Slide on the front cross bar and then pin it.(does that make sense?) No bending required. Just coping and a weld. You could actually have mast rake adjustment if desired. It could also be all aluminum if in a fresh water application.
Pat,
I was ready to roll out a similar design to yours. I'm "seeing" where they're going with this and warming up to the idea. We'll see how the testing goes. We know we can always fall back on a mechanical connection. Thanks for pointing out the AL freshwater option.
Are there kids who can understand AND PRACTICE rule 14? <img src="http://www.catsailor.com/forums/images/graemlins/crazy.gif" alt="" />