Dave,
Building a carbon wingmast would be easy if,
1. you knew the tolerances to build it to and
2. you had a wingshaped male mold.
You can get a good catamaran architect to tell you (you would probably have to pay him) the layout of the cloth and how many layers and how to orient them and such. Applying the cloth is the easy part.
The hardpart in my opinion is the male mold.
You could make a male mold out of lightweight foam and wrap it in carbon.
You could make a light weight ply section like the one you have any wrap it with carbon.
You could make the male mold out of machined polished aluminum and wrap it in carbon and remove it, but by this point you'd be in the mast building business.
I'd say it would be easier to fix the one you have an wrap it in carbon to make it stronger.
Bill
make a quick easy FEMALE mould. it is the only way to do it. the engineering is easy. the mast track is easy. dont get worked up because it is a mast.
i snapped an aluminium spar and had no option but to build one. i threw a glass mast together with a bit of help in a weekend. cost me about $200 canadian and lasted for four years.
i am not saying that this should be done here, but it is an option that should be explored.
