Thanks to DW your clear instructions on the vid for the boom mod were really good.
Just made my 5.0 boom with a 25/22 OD/ID carbon tube, same weave as the recommended one. The end piece was hellish difficult to get out of the old boom, I put a rope through the end and around the hook and tied it to a pole and twisted it out. Sanding it down took an age as well, ended up using a coarse file to start with then went down to fine, then sandpaper.
I thought the pop-rivets might not work so well in the inside of the carbon tube (despite the glued stiffener piece for the old boom) so I thought about adding an inner sleeve to rivet into but gave up on that idea and put a through bolt in instead; partly because I don't trust it won't leak and redrilling the rivets to let water out and redo the plug (that I put in with marine grade silicone) will ruin the plastic headpiece eventually. A bolt can be easily unscrewed.I found a can of spray foam as a sealant but it was truly dreadful; ended up getting rid of it and using the silicone.
I've replaced boom grip on Windsurfing booms before but DWs taping tips were great, made it even simpler. Had to bevel the edge myself though, difficult to get straight, you really need a long steel straight edge. All in all it looks good, hope I don't fall on it day one and bust in (man the tube is thin-walled!) and I hope it helps my wife get out on the wing, she was struggling a wee bit with the original boom (although to be fair it's probably more due to the 5.0 size than weight). Did the 4.0 and If willhave a crack at another one for my 6.0. A friend got me some 22/25 ID/OD 3K carbon tubes, works really well.
Thanks again.
I have a question:
Does anyone think (or has done it) I could reduce the plastic front boom weight further by drilling a few strategic holes in it without weakening it too much? I was thinking around 8 x 8mm holes in the curved front piece (4 each side, it can't be loaded that much, I'm a civil engineer, but not a mechanical one) and maybe a few in non stressed parts of the flat?
cheers
k


