Hi Sam,

I doubt about the 2% benefit of a wing mast. As long as your sail fits to the mast and the mast is light, strong (it will not break) and flexible (it can be trimmed over a wide wind range), everything is fine. In other words a cut Tornado section sounds reasonable. For example Landenberger gives you some advises how to measure the flexibility of the mast and he will cut you a sail to this mast, but I am sure other sailmaker offer you the same service.

Crossbeams: You can make your crossbeams form CFRP in your workshop as well, or you can buy standard alu extrusion 100mm diameter. I think a H16 mast is to flexible for a crossbeam.
Self-tacker: Buy a straight track, go to a smith with a machine to bend metal.

Rudders, boards: I can take a measure next Saturday, if you want. I can give you sections which I have developed for Tornado rudders as well, however they are thicker than standard section (yet have less drag), so you may need custom rudder heads. Rudders and boards shoud either have a high density core (as wood on Tornados) or spars to avoid core-crushing. If not you need significant skin thickness of CFRP. I think that the cheapest and yet light way to do is to have a wood core (CNC machined from a good carpenter shop) covered with glass fibre (you may add Aramid on the leading and tralning edge).

Good luck.

Cheers,

Klaus