Ian and Rich..
First, I am referring to my picture in post #3 of the Nonsuch mast with the large hole in it. Nonsuch boats use an un-stayed rig and the part of the spar at the deck and below the deck are very, very critical loading areas. Any holes drilled in these masts put the entire spar at risk if they are drilled incorrectly or in the wrong place. The current spar manufacturer would not say that hole was safe or even come close to saying it was and if fact told me, in no certain terms, to walk away from that boat.My point is to show how sensitive a spar can be even with a nicely drilled hole, no jagged edges, in a very thick spar. That spar, other than that hole, was nearly perfect yet the spar manufacturer basically condemned it as a liability waiting to happen. Now a stay-less rig and a stayed rig are quite different but that corrosion is about as bad as I've ever seen on a mast. If I had to take a wild guess I might land on the theory that perhaps there was a frayed mast wire accelerating the corrosion.. I've seen corrosion that bad at a mast base but never in the middle of the spar..P.S. That mast really looks like it has cancer and I'm somewhat horrified that a "reputable" spar shop told you it would be safe. The area shown in photo #1 looks far larger that what the eye can see if you go by the condition and dis-coloration of the paint around that hole.