Join Date: Sep 2001
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Not sure what masts and furlers cost but I am right now the process of redoing my standing rigging:
If you break convention and rig it with galvanized aircraft cable, you can save a lot. The cost to replace my entire standing rigging, including the tools, hardware, books/learning, and maintenance goop for a heavy duty 40' ketch rig, came to around $400.
I recommend some intense research-- shop around (places like Fehr Bros or Erigging) and piece it all together to see what it will cost. Those sta-lok fittings get awful pricy (or you can splice ends yourself and still have a rig just as strong)
Book recommendation: the Complete rigger's apprentice, by Brion Toss. Lots of people think he's a heretic but the engineering behind his stuff is completely sound, especially as it pertains to galvanized materials in rigging.
You could make your mast out of *gasp* wood! Do it yourself, the old way, it worked for centuries. Book recommendation: Bueller's Backyard Boat Building. Just as good for outfitting/refitting a boat as for building one.
Sails, go with Rolly Tasker. Best prices and great products. A new main and mizzen (40 foot boat) will only set me back $1800 delivered. Years ago I had a new Rolly Tasker mainsail made for my 25 footer, and I can vouch for their quality. Top-notch stuff.
In the end, you may be able to make it work just fine for around $10,000. Won't be as pretty, but it will do what you need it to do. Me, personally, I respect the ugly boats that have been everywhere for a few bucks, more than the million-dollar sparkly ones that are too afraid to be sailed.
A few good solid months of planning will save you a lot of time, money, and future effort. I devoted a lot of time this winter to figuring how we would refit our boat (after living aboard for several years, we had a lot of ideas on what to improve and what needed work).