I bought my sailboat in France.  When bought it had solid timber masts that had succumbed to dry rot; when I cut the butt off the mainmast and dropped it to the hard it shattered into a million pieces.  So, the search to replacement masts began.

First I looked for solid timbers, but everyone I spoke to that dealt in solid round timber said "Yes, but you have to buy a minimum of five (or ten)."  Then I looked for aluminum and all the sources I could find replied "Apologies, but we can't verify the safety of your installation, so we won't sell to you.

I finally drew up some plans using PJR as a reference and shotgunned the plans out to spar builders in the UK.  I finally settled with Collars (https://www.collars.co.uk/), aka Freeland Yacht Spars, located in Dorchester on Thames, Oxon, UK.  The price was steep, but after more than a year of searching I went with them.  Both the fore and the main were 220mm at the butt and 110mm at the top.  The fore was 11.5m total length, and the main 13.5m, both hollow.  The quality was good and I was quite satisfied with the end result.  Jeremy Freeland at Collars had built similar masts in the past so it wasn't a mystery for him as it was for some of the shops I'd sent drawings to.

The photo is Tanstaafl with the masts stepped.

If transport from Germany could be arranged, I could help with the adress of a private seller of several flag poles (aluminum), with a bottom diam. of 145-150mm, 4,5-5mm wall and 11,5m in length.

I bought mine there.

They sell them for €200

Regards, Thomas

We purchased a lamppost from the Aluminium Lamppost Company (ALC) in south wales... But they become worried we were using it as a mast and could not provide the relevant computational docs (as you would have if it it really WAS going to be a lamp post) - so you might need to be circumspect...

Our blog has a number of posts concerning this (check the "rig" menu for details... here are a couple of links:

About the rig

mast on trailer

Best of luck!

Anonymous wrote:

I'm sort of coming to the decision that making an 8 stave, birds mouth wooden mast might be my best option, if I can source some good timber.

I'm sure there must be some people here who have done it, do you know of any?

Tony Brown, Tapatya and Alan Mulhollland, Wave Rover both have YouTube videos on how they did i.  Gary Pick did articles for the magazine.  Ditto Bertrand Fercot.

 Arne Kvermeland gives detailed instructions also

if you put the search term “mast” into our Knowledgebase (which now contains nearly 1400 links to junk rig resources) here is a selection of what you get - about half are relevant 

Anonymous wrote:

Hi Kevin,

Thank you, that's interesting. The price is a little eye watering unfortunately. My budget is about £3K for the entire project, including sail!

And no doubt they would add a hefty transport fee too.  But perhaps they’d negotiate to get their first introduction to junk rig masts?  Anyway, as I said, I posted it more for general information than thinking it would meet your particular needs.  

I wondered where sailors of Freedoms get mast replacements and as I’m becoming a reluctant fan of AI, I put that question to ChatGPT.  Interestingly, among other true but not very helpful hints, it suggested that inspiration might be found at the Junk Rig Association website!!