Oy
Hello,
First, it should be just about impossible to tear a hole in the mast by "overtightening" the shrouds, even with the extra leverage provided by extending the bolts; it is likely that there was insufficient bearing surface/strength at the mast to begin with.
Next, it is amazing that the tear extended an inch or two. Wow. And welding would not, as you noted, be helpful.
Instead, consider fairing the edges of the tear, and then screwing a layer of aluminum over the damaged area. Make it a big thing, with a goodly number of screws to hold it. You should probably move the hole down to the bottom of the tear on both sides. Drill for the new tang, but get the kind with massive bushings and/or internal reinforcement.
And of course, get rid of that useless step.
Fair leads,
Brion Toss
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