Sun Cat spars

[DanM]

If you want to cut the mast yourself,  I believe you could do it on a well-set up miter saw ("chop saw"). I cut the aluminum booms on my Sea Pearl this way and it worked out well. Personally, I wouldn't try to make a perfect cut by hand, though if you must, I agree some kind of jig would be useful.

[jdklaser]

it's more than just making a cut.  It has to line up properly using the mastender system. I've done tons of aluminium cuts on dinghy booms and masts.  Here you are dealing with the true stability of the rig.    Give the folks at Hutchins a call before you try a do-it-yourself mast replacement on a suncat.  You might just save yourself a grand.

[DanM]

Sounds like good advice from someone who knows.