Hi Taz,
I'm familiar with plug welding, but would ideally like a solid piece. My mast must not taper, at least for most of its length, so the gaff jaws or saddle don't get all baggy at full hoist. If I have to, I can have a mast that ends at the hounds (where the lower shrouds come in), and then use a skinnier pole above that--but that's a complication I was hoping to avoid. I like simple.
How 'bout (for your project) doug fir soaked with CPES epoxy, (available from Jamestown Distributors), then varnished a lot before the mast is stepped? once the mast is up, if you keep a good several coats of Mother's carnauba wax (Mother's smells soo good!) on the varnish, the sun won't eat it up, and a coat of wax every so often is almost a joy to apply.
If I have to go wood, I'll ceratinly do that. By the way, Bird'smouthing is exhaustively discussed on the wooden boat forum run by Wooden boat magazine, with useful links to pictures. Google it and see--pretty cool stuff.
Best,
Ben
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