Just for information. The primary concept of composite structures especially carbon is not to add more to get the structure stiffer or less for a more bendy structure. It is determined by the lay-up schedule and the materials used. An example would be if you used only uni-directional cloth and laid it up in one direction (0,0)the lay-up would be stiff in the 0 degree direction and flexiable in the 90 degree direction relative to each other. If you wish to do a proper repair and you do not know the lay-up schedule of the structure, then you should scarf the area of damage and identify the amount of plies in the lay-up and the direction the layers are laid ( i.e. 0, 90, 45, -45 degrees) . The strength and resistance to bend is achieved by the continues fibers and the direction they run. To return back to the original properties you need to reconnect the fibers that were severed when broken. To do this you remove the damaged area by scarfing (tapering) the damage then replace the layers, smallest first then larger, and in the proper direction of each layer. In designing a repair of a structure the designer would add one to two extra plies depending on the structure and repair because you can not physically reconnect the broken strands. Following this procedure will get you as close as possible to the original structures properties. This is a basic overview of how we would repair a stealth fighter, a 757 airliner, or any other basic composite structure.



Hope this helps, it is always great to see other ideas of doing blind repairs. The repair I did in this photo was a two stage repair. Since it was a hole through the structure it could not be bagged initially. So the hole had to be sealed from the back side unable to see (blind repair) before the surface could be repaired using a vacuum bag method. Good luck with your mast.

Carl
Saylor Specialties
www.saylorspecialties.com