Senior Moment Member
Join Date: Jun 2011
Location: West Vancouver B.C.
Thanked 118 Times in 113 Posts
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A weldment laid by a competent, preferably certified, welder will not compromise the strength of the tube but, in fact, restore it. A mechanical fastener will not suffice for the prospective tensile loads the spar will be subjected to. (I appreciate that you may be/are looking for a less costly option for this repair but this in one time when the lowest bidder is not/"ain't" an acceptable option). Again. The proper repair should not be that costly--relatively speaking (particularly relative to loosing the whole darned rig!). N'any case, Your yacht/Your call. Good luck. FWIW...
Hylyte is absotively correct. A properly welded joint is indistinguishable from the parent metal. I once had a double rail stern pulpit that had been bashed against a tree by a "Boat mover". I took it to the best S/S shop around here (Irion) who had in fact built it for me. The bends & kinks were right in the corner radius of the tubes. I assumed they would have to cut the rails off and replace them but instead they merely cut out the damaged sections and welded in new curved pieces. Once they were polished you couldn't detect where they had been joined - and I KNEW where. They were perfect.
From what I understand, aluminium is easier to weld than S/S as well. Both these metals have the rep of being exceptionally difficult to weld well but that goes back to the days of stick welding. MIG & TIG welders have made welding them much easier - although they still require skill, just not a "magic touch" like the G.O.D.'s.
I, myself, personally intend to continue being outspoken and opinionated, intolerant of all fanatics, fools and ignoramuses, deeply suspicious of all those who have "found the answer" and on my bad days, downright rude.