I also can't recall where I last saw the ultrathin aero-grade ply.. Think it was at the local hobby shop.. Used for model gliders and planes..But the issue will be scarfing 1 mm thick ply!! <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" />
That sounds like an ungodly amount of work to do right. When you are all done the you have 1 mast that in all likely hood is not quite what you really want.
Why not build a gypsum/screed mold and lay up a traditional full carbon stick? The process for the mold is very simple to do at home and could be used for several attemps to dial things in. The actual mast build process is fairly straight forward as well. The biggest A class mast builders do not use autoclaves, even though ideally they should produce a slightly better finished product.
