Broken Mast...Repair or replace

[Douglas]

I have been studying a similar situation, myself. Well, if your mast is in sections already, you surely can put in another sleeve and re-join the two ends.

Yes, additional weight aloft is a valid concern, and should be considered.

Yes, without the benefit of photos, it is hard to visualize your exact requirement.

If you need to get back out sailing quickly, and save money, think repair, before thinking replacement.

Of course you will be checking the other turnbuckles for potential failure too.

Try to stay away from welding on the mast section itself.

A main reason for total mast replacement would be many dented-buckles in the mast wall, in various places. Aluminum mast "metal fatigue", in structurally critical places, evidenced by line cracking away from fittings, and excessive crazing on an anodized aluminum mast surface near structural parts or elsewhere.

[Brion Toss]

Hello,
Great post from Douglas. I'm just curious to hear more details, for forensic reference. See, every rigging failure, though it might cost you dearly, can be an opportunity to learn how to prevent other failures, for you and the world. So tell us more about the turnbuckles, sea conditions, state of tune, age of rig, etc., okay?
Fair leads,
Brion Toss