Windsurfer mast for Hobie AI

I've been trying to put together a second AI from a Hobie Adventure (older version of Revo 16), and it's complete, except for the mast. The official Hobie mast is over $800, and I don't think it is even possible to get the pre-2015 version. So, I decided to try a windsurfer mast.

I found a used 460cm (15' 1") 90% carbon mast for $200 (no shipping, no tax), so I figured it's worth a try. The mast is exactly the same length as the Hobie mast, it's about 1mm narrower at the base, 2mm narrower at the top, the thickness at the center coupler is 1/16" (Hobie is 3/32"), and it weighs 3.86lbs (about 1/2 the weight of the Hobie). I did a few flex testing experiments, and as near as I can tell, the windsurfer and Hobie masts are virtually identical in that respect.

I bought the Hobie mast base and collar and attached them to the windsurfer mast (rivets for base, G-flex for the collar). The mast top piece seems to be currently unavailable, and since it fits inside the mast, it would not work without major modifications anyway. So, I made a little dohickey out of a solid piece of 1.5x1.5x3 inch piece of starboard plastic (not easy without a lathe...). That slips into the top of the mast. I've also got a mast topper that I use, which is the secret ingredient that makes it possible to fly a second sail (jib/genoa or spinnaker), and I figured out how to add that to the top. That was actually a bit tricky, as the sail is not a standard Hobie sail--it's from Intensity Sails, and was super-cheap (like $200, although, unfortunately, they don't sell AI/TI sails anymore). The non-Hobie sail has a narrower sleeve, so I could not slip 1.25" PVC pipe through it, and had to use some narrower (but, supposedly, extra-strong) below-sink PVC instead.

The only things remaining are to spray paint the mast-topper tube, and put one bolt thru to connect to the top of the sail, which should be done in a day or 2.

I might try to replace the mast-topping tube with aluminum tubing. I'd also like to redo that white starboard plastic piece in aluminum, but I don't have a metal lathe, and that would probably be beyond my limited angle-grinding skills.

The lighter weight aloft will be great, but a broken mast would certainly be no fun. A jib definitely puts some extra stress on the mast too.

I was hoping to test it out this weekend, but it looks like the wind will be practically zilch after Wednesday, so I might have to wait a bit to see if it'll hold up. In any case, I still need to find some battens, so if anybody knows where I can get 3/16" fiberglass rods in 10' lengths locally, LMK. I can find them online, but shipping is pricey.

A bunch of pictures...
 

These pictures show the windsurfer mast next to my current Hobie mast...

Tap Plastic has 3/16" fiberglass rods, but only in 6' lengths. I used short section of brass tubing to join pieces together to make get the proper length for the battens.

It's now ready to sail--just waiting for some decent wind to test it out. One thing I am sure of is that I'll feel very patriotic sailing this boat...

That looks really nice!

It will be really cool to see her rigged and try to keep up with you on the water  . I've could really use a mast adapter, I'd like to have something like a 3ft pole I can drop in the mast hole.  I envision stretching ridge line tarp from front to rear for the sunny and rainy days.