Got the boom back on the boat uneventfully....it's still heavy!! Painted with several coats of Petit EasyPoxy. Nice paint but hard to work with in the 90+ degree heat. Pretty and white again. And no broken welds or corrosion now!
In case you noticed, we turned the boom upside down because it was easier to rea-assemble most of the attached hardware with it in that position. It was easy to turn it the correct way for the final installation.
About 5 hours later the sail is back in place, the lines are run thru the boom and the new zipper is once again functional in the sailcover. Was more difficult than I expected!