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Have found and read a few discussion.

I have a front beam needing replacing, Mast beam okay and stern beam probably salvageable.

Thinking of making new beams according to the plans but from aluminum so not just a rectangular section or cut down mast tube but following the plans but in aluminium not glass and ply. Has it been done, should it be done? Another option thinking of using LVL beams as a box section and glassed for protection, ugly but simpler. Or should I just get itchy and follow the glass over ply version?

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Aluminum can work, but you can’t just swap it in, you’ll change stiffness, load paths, and fatigue behavior. LVL/glass is heavier and ugly, but predictable. If you’re not a structural engineer, stick with the original glass/ply.

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