Ok, I finally worked up the nerve to climb up the mast to rebuild the halyard box. A couple sheaves were frozen and the second spin halyard sheave wasn't there. Not as easy as I had hoped. I rigged up a solo climbing setup with ascenders. Six time up and down the mast, a climbing harness is not a good idea, it's not built for comfort like an actual bosun's seat. The screws came out ok, I was afraid they'd be seized, the threads were all a bit worn down though and when I put it back together, one of the 10 holes stripped. There's gotta be a better solution than stainless hardware screwed into aluminum. Hopefully It will hold until I can pull the mast next year.
The pins for the sheaves were not press-fit as others have reported. The ends were peened over and try as hard as I could, I was unable to peen the replacement ones from rig-rite down as short as the original ones. And one of the pins for the sheaves is located slightly under the flange making access nearly impossible. I thought I had it pretty good, went all the way back up the mast and the box wouldn't fit in because the pin ends were sticking out too far. I ended up using a grinder to cut the ends down nearly flush, that left a bit of a 'rivet' end to keep the pin in place. fortunately there's no lateral forces on the pins.
As I have a roller furler, I moved the second jib halyard into the second spinnaker slot. I had thought about running another halyard so I could have 2 of each, but I couldn't find a good spot on the mast to cut yet another hole for the exit. I'm leery of having the holes not staggered enough.
Erik
Mango Madness
#185
