I have a little experience with composites. I'm not sure that drilling holes in the composite is a good idea unless the composite was specifically designed for it.
Drilling a hole and loading it with a bolt or rivet will cause very high stress and probably induce cracks in the composite. Usually the manufacturer will lay up a metallic re-enforcement between the layers in preparation for any such holes.
Maybe Hobie can comment on this...
But meanwhile, you won't catch me drilling anything into my $700 comp tip!
I've had my '11 getaway for just over a month. Went sailing this weekend, and as we de-rigged i noticed the comptip had come loose. Since the epoxy is really only under load when the mast is not vertical, probably hobie could put grooves on the comp tip and inside the mast (around the circumference) so that the epoxy will fill these voids and create solid connections.
I'm guessing when we pull out the comp tip, it is covered in cured epoxy but the inside of the mast is fairly clean of epoxy?
The way it currently is, the epoxy probably doesn't bond to the smooth aluminum very well so that when the mast is horizontal on a trailer or being rigged, the bending moment shears the bond. If the epoxy was shaped to interrupt this smooth bond I think it would actually have to shear the epoxy which might hold a lot better than the aluminum-epoxy bond.
Now that i think about it, as a retrofit, maybe putting a wire brush in a drill and plunging it into the aluminum would create enough texture within the aluminum for the epoxy to grip better... I'll have to try that.
Wow, what a mouthful. Sorry!