Per your description, it sounds like the strut is broken in two or more places. Is this correct? I would attempt to patch the strut with aluminum pieces and small screws. If you have room at the particular crack, use a patch piece on both sides (double splice). If the strut is really messed up, I'd replace the entire unit with a new one. I can't really think of a practical way of avoiding cutting wood. Just enlarge the cut-outs on the turtle deck until the strut passes. Patch the turtle deck after the new strut is in place.

As far as material goes, it's either thicker aluminum, or steel. I would try thicker aluminum first. If you're really eager, you could try to mold a fiberglass or carbon strut.

BTW, how many hours do you have on this bird? Do I have a strut failure to look forward to in the future?