Originally Posted by sailingdog
I'd point out that most modern spars are heat-treated grades of aluminum alloy and gain much of their strength from the tempering process. Cutting and re-welding the spars are going to cause them to lose much of their strength unless you can re-heat-treat the spar....which I doubt.
Understood, but as I understand it, the top 5-6 feet of the spar is under mostly compression load. The strength lost won't matter as long and as there is a fully penetrated weld things will be good.