Sorry to see you are having trouble with your TI mast.
Need a bit more info to give you a proper response.
- Year of your TI
- Any pics of the mast receiver attachment point
- Pics looking down into the hole that the V brace screw goes into.
- Pics of the V brace set screw by itself next to a ruler to verify length.
I am assuming you have read the sticky post on this subject (V Brace set screw):
https://www.hobie.com/forums/viewtopic.php?f=71&t=66542 If not recommend reading this.
My experiences:
I sail in rough offshore conditions with the sail reefed a fair bit of the time. The V brace set screw on the bottom eventually wears out. Hobie did a redesign from a 1/4 inch stud to a 5/16 inch stud starting with 2016 hulls.... For good reason... the 1/4 stud just is not up to the forces.
I have had my TI mast tip over (break off from stud in the bottom and the mast leans over about 30 degrees). Note the mast did not break. This was the older 1/4 inch stud. I my case the actual fail point was in moderate wind conditions. Upon repair and with the expert help from Andy LeVine (Tackle Shack (Florida)) we were able to remove the broken embedded stud (nothing sticking out) with a new 1/4 inch V Brace set screw and replace the mast receiver which was also had excessive wear. My failure was from an accumulation of wear over many sails.
I do an annual inspection on this bolt and replace it if there is any wear. I also inspect the turnbuckles for proper tightness. I now sail the 2022 TI with the larger 5/16 set screw.
The turnbuckles should have equal tension (turns) on both sides. Not pushing down or pulling up (based on my TI). Tighten the V Brace to get it stiff without expanding the hull. Then lock the nuts. Others could comment.
So....without any additional information....my best guess.... a) you have a broken V brace set screw stud in the bottom of the mast receiver....maybe only one or two threads are catching above the break point. Again... this is just a guess based on limited information. This is based on your comment that you were able to reattach the V brace set screw but it failed again in rough conditions... thus may have a hidden broken set screw. OR b) you have a partially stripped receiver nut (what the V brace set screw goes into).....