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Need the genius here

I would like to extend my current (plate 90x165mm) foil mast by about 8cm. I have been thinking about adding something between the board and the mast plate by this amount. I thought about aluminum block, but it seems excessively heavy, 110x230x80mm is already 4+kgs! according to internet calculator, which is way too much. The idea was to make 4 threads on both sides of the block and attach the foilmast on one side and obviously the board on the other side. This would be very solid, but the weight kills this. I don't know how much weight can be sliced off by taking the material off inside of the block, but still think it would be quite heavy solution :/

Any ideas how to make this kind of block between the mast and board, please?

Thanks and good health to all!

You simply don't.

Even a tuttle adapter to plate has a noticeable added drag on takeoff and touchdowns. So adding a big block between a plate and board would seriously impact your drag in a way that need more kite power to get going or have less low end.

Why not extending mast near fuse?

Long M8 bolts and off u go...

You could make 2 wooden 'planks' that are shaped like oversized twintip fins, 8cm high, about 2cm thick, 20cm long or longer. Top of those 'fins' goes into the board, bottom to the mast plate. If this seems too unstable, have some foam in between, wrap the whole thing in fiberglass or carbon, make front and back angled for less water resistance.

Drag at touch down would be huge. You wont achieve what you want to achieve. Get a longer mast. Or live with the shorter mast

I haven't tested but yes it should be possible !!
In which material is your existing mast ?
You could try a "mini me" : screw a flipped alu plate on your existing one + an 8-20cm alu mast (cut to exact length and re-threaded)... with plate on the board side !
90 x 165 alu plates cost 25-30 usd + shipping these days.
You should be able to insert a home made wing between the two plates for the low wind days, 600 + 400 = 1000cm2, same role as line extensions for a kite.