I ran into this problem this summer when I rehabbed Vee Jay 2's boom ... the forward block sheave was locked solid. Checked Vee Jay today here in Naples and not only was the sheave locked solid being compressed by the becket ... also was rigged as a 2:1 instead of a 4:1. The Kenyon block looked under spec'd and is probably a problem for anyone who hasn't checked it out.

Naurally there are 3 SS screws into each AL boom end fittings. Two I was able to unscrew, three broke, and one was finger tight. Followed old practice of grinding smooth ... redrilled a half inch away, tapped up to 1/4 in. and reassembled.

[don't really need to open up aft end of boom as the needed access is at the mast end of the boom]

I replaced the blocks inside the boom with Harken 40mm Carbo blocks and thru bolted the gooseneck end, two seasons and no problems to date.

Wish I'd read this when it was first posted. Took my boom apart today to find both blocks totally seized... No wonder we've been struggling with it. I look forward to my APS package in the mail and more beautiful sail shape this summer!

The original specs used only a two to one advantage I changed mine to a 4 to 1 reduction years ago makes a huge difference in getting the outhaul set when under load If you are taking the boom appart also change out the stainless wire back to the end of the boom its cheap and a real PIA to change if it breaks

I also had problems with the blocks being seized up. I added an extra block to the system to get 6:1. Perhaps a bit overkill, but very easy to adjust in heavy air. A few pictures before putting everything into the boom are at Hullabaloo Outhaul Repair.

Hullabaloo is on target, though I have a few quibbles. Counting the turning block where the purchase exits the inboard end of the boom the original setup was 4:1. Adding 2:1 makes it 8:1 which is plenty.

Since you are updating, you might replace the old school wire tail with a 1/4" spectra single braid like Amsteel and use the same line for the 2:1 part of the purchase which takes the highest load. For the 4:1 part try 5/16" double braid like Sta-set which is easy on the hands. As noted in a previous thread adding a Ronstan RF5 Swivel 180 Cleat allows the crew to adjust or release the outhaul from either rail.