Originally Posted by hpeer
I think the bigger issue with reforming the groove would be metal fatigue. Once bent the aluminum
will loose strength.
I believe you can find a relatively, but moderately ugly fix by attaching a doubler over the track and somehow attaching to that.
A lot like your first response.
On closer inspection
of the mast, the upper most widened part(outlined in green circle in the pic) is actually the mast luff entry point. The widened groove segment below this seems to explain the gooseneck distortion on the end of the boom. The boom groove is perfect. So i think that the actual sail integrity in the track is not a problem and that is a relief(especially for cruising).
The screw going through the groove I haven't figured out yet unless the previous owner had this through the Cunningham hole( and please don't let it be through the sail itself.), since the groove doesn't need closure here. It appears that because the widened lower groove was stretched, and the necessity of the screw-through-groove, he had trouble with his gooseneck which would have normally provided downhaul.
It means I'll need to do a smooth out of the screw hole within the groove somehow and maybe fill that with epoxy(don't know anything about brazing aluminum) otherwise there is danger
of cutting the cord.
I'm optimistic now, since I know the problem is narrowed to the gooseneck and the lower groove. The best thing to do i guess is to lay it all out on the lawn with the mainsail
and just see what is affected. The lower groove i could use less sensitive repair since it holds the cars of the gooseneck, and also because gooseneck kits are available, complete with gooseneck track sliders. I can always use a manual downhaul/reefing system and a fixed gooseneck too which would be a bummer.