I recently had my sailworks boom break. Fortunately, I had only just launched from shore and was able to get back easily. When I inspected the break, at the join of the head and the allo tubing, there seemed to me a design flaw which contributed to the breakage. Inside the tubing right at the break was a piece of foam about 70mm long. I am not sure what was the purpose for the foam, but it seemed to me the foam was retaining the moisture inside the tubing, which in turn contributed to the heavy amount of internal corrosion. The corrosion had reduced the wall thickness at a a critical junction on the boom. The boom was about 4 years old. Has anyone else encountered this problem
Col I've never had a Sailworks boom or even seen one here, but I think 4 years is great going mate.
Without the 70mm of foam it may have lasted twice as long. I sail on Lake Macquarie, so it would not have had the heavy use you may have experienced. My point was it was a simple design fault which appeared to serve no purpose other than speed up the corrosion process.
Col when I got my carbon boom I put my Chinook alloy one away as a spare and or for my young fella, I dragged it out last weekend for him after 3 years little use and noticed under the grip in lots of places bulges from corrosion, it's going into the bin.
I always warn people who come back to windsurfing after a couple of years, not to trust their old boom. I understand your frustration if it's had little use.
Have a look at these alloy booms http://www.windsurfingsales.com.au/products/booms/gunbooms.php only about $150, I know of a few of these and seem ok, I'll be getting one as a spare and or for my son. Carbon booms are fairly bullet proof but aren't cheap and prob not worth it for a lot of sailors.
Hope you're back on the water soon 
You're right Col but unfortunately most booms use foam or plastic plug to stop the extra kg of water when the boom fills up. And yes booms mostly fail at the plug/end of foam or at point where head insert ends at boom arm.
So whats the alternative? I'd rather a boom fail every year than go back to the days that booms fill with water. I've often considered maybe they should use something like an expanding foam which bonds to the alloy but then you don't know how the foam will react with the alloy and also after repeated flexing the foam would seperate.
mkseven, There is a plug in the boom which stops the boom filling with water. The foam was located in a space which would have about 1/2 cup of water. Not likely to seriously load the weight of the boom. I remain puzzled at the purpose of the foam.
firebob I hope to pick up another boom shortly and will be back on the water by the weekend
Happy New Year to you all
