Any holes in an aluminum tube for attachment of anything can develop "localized corrosion" which is just another way to describe the white powder corrosion aluminum is famous for when water
can seep into the confined area around the bolt/screw or under paint
that is not intimately attached to the metal.
- - Bolts or sheet metal screws that are too large can apply radial pressure to the tube and start local spider cracks which when over stressed (accidental/crash jibe) will allow the initial crack to propagate around the tube. The use of the proper size bolt/screw is essential along with coating the bolt/screw with anhydrous lanolin such as Lanacote, Tufgel or other similar products.
- - There are quite a few "boom brakes" on the market to help eliminate the problems of shock loads during accidental/crash jibes or tacks.
- - If you have a boom vang/kicking rod and keep it very tight to pull down the boom, a crash/accidental jibe will put severe stress on the boom at or just beyond the attachment point on the boom.
- - As others have mentioned booms really take a beating when not properly managed to reduce shock loads. A flogging sail with a loose sheet also whips the boom every which way introducing shock loads. It is advisable to really pay attention to what you are allowing your boom to do in order to avoid that mentioned hazard of having a boom break while out in the "middle" of the ocean.
- - Be especially careful if you have loose footed mainsail
as when/if the boom snaps you will have two ragged edge poles swinging wildly about trying to find your or anybody else with you's head
. My boom has sail slides along the boom so that when it snapped in half the sail kept the aluminum tube under control.