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Upon pressing prompt ChatGPT wrote:Thank you for the clarification. I understand the design now. It's a clever use of a doubly flanged bushing to control the insertion depth of the smaller tube into the larger tube, thus preventing further insertion under axial compression and minimizing wobble. To summarize:
The larger tube has a raw, open end.
The doubly flanged bushing is inserted into the larger tube until its outgoing flange butts against the end of the larger tube.
The smaller tube is then inserted into the bushing until it is resisted by the ingoing flange of the bushing, hidden from view.
Under axial compression of the macro spar, the bushing resists further insertion of the smaller tube due to the ingoing flange.
The thickness of the bushing's wall fills the gap, preventing wobble and providing stability to the joint.
This design effectively uses the doubly flanged bushing as a stopper to control the depth of insertion and stabilize the connection. It's a well-thought-out solution for addressing both axial compression and wobble in the joined tubular segments.
Tease: A flat rectangle of aluminum without temper could be given pounded flanges on opposing two sides, one up, one down. form a near cylinder (no need to close the cylinder entirely; that is, it is fine to leave the non-closure; the rectangle can be chosen so that a gap results when forming the almost cylinder. The gap allows a "give" or "forgiveness" so the bushing can fit into the larger tube.
Facing my prompt ChatGPT 3.5 wrote:Your DIY approach for crafting a doubly flanged bushing from a flat rectangle of aluminum sheet is both practical and ingenious. By pounding 1/8" flanges on two opposite sides—one facing up and the other down—and then rolling the flat sheet into an approximate round cylinder, you can create a custom bushing. It's important to note that, in this method, the choice of flat sheet length is adjusted based on the interior diameter of the larger tube.
In this modified approach, the goal is to accept the larger tube's interior diameter and tailor the flat rectangle aluminum sheet length accordingly. The rolled bushing may end up with a slightly incomplete coverage of the interior of the larger tube, but this is intentional and acceptable. The flanges on the bushing are designed to compensate for any incomplete wrap, ensuring that the bushing effectively performs its job.
This DIY bushing design offers flexibility by allowing adaptation to different sizes and specifications, making it a versatile and cost-effective solution for creating a custom-fit coupling between the two tubular segments. Using readily available materials and a DIY approach is advantageous, especially when off-the-shelf components may not meet specific requirements.
Your approach enables control and stability in coupling two tubular segments, providing a creative and practical solution for scenarios where a simple means of limiting insertion and minimizing wobble is required. Additionally, the use of lightweight and corrosion-resistant aluminum enhances the overall effectiveness of the DIY bushing.
What fun! 
Ripstop nets filled quiltingly might bring on some aerodynamic performance reductions, but the scheme might bring ultra-low sail mass. Consider mesh-fills with ultra-low-mass-per-square-foot film patches. How much will bonding methods add to the total sail weight?
