Complete halyard replacement

[RAGTIMEDON]

Rather than hijack a previous post (I had it all typed and then deleted it) I decided to start anew and ask advice of the forum. I have previously had rope halyards on a 25 Macgregor and a 28 O'day but now have wire-rope halyards on a 37 Endeavour. I much prefer the all rope, and know that I will probably need to replace the sheaves at the masthead. The rope is not the problem, but how does one determine proper size for the sheaves? I suppose I need to get someone aloft to measure the shaft size, the size of the groove depends upon rope diameter, and what determines the proper outside diameter of the sheave? Who stocks sheaves, who is easy to work with to get advice and ordering info? My halyard winches are badly worn because a foolish previous owner wrapped the wire down onto the drums. Is there a chance I can replace them, or have them machined to restore them, or is it more practical to replace them? If I replace them, I may extend the halyards back to the cockpit, but then how does one attach turning blocks , rope clutches and the new winches to the coachroof solidly enough to withstand the strain of the halyards. Then I have the problem of closing the holes on the mast left by removal of the old winches! Seems like every question leads to another question! Thanks for your advice.

[sailingdog]

Originally Posted by RAGTIMEDON

Rather than hijack a previous post (I had it all typed and then deleted it) I decided to start anew and ask advice of the forum. I have previously had rope halyards on a 25 Macgregor and a 28 O'day but now have wire-rope halyards on a 37 Endeavour. I much prefer the all rope, and know that I will probably need to replace the sheaves at the masthead. The rope is not the problem, but how does one determine proper size for the sheaves? I suppose I need to get someone aloft to measure the shaft size, the size of the groove depends upon rope diameter, and what determines the proper outside diameter of the sheave?

Working sheave diameter is usually roughly eight times the rope diameter. So, if you have a 3/8" rope, then you need a 1/2" x 3" sheave. Going a little larger is generally better, but you don't want to crowd the masthead fitting.

Who stocks sheaves, who is easy to work with to get advice and ordering info?

You can probably get the sheaves you need from Rigging Only.

My halyard winches are badly worn because a foolish previous owner wrapped the wire down onto the drums. Is there a chance I can replace them, or have them machined to restore them, or is it more practical to replace them?

Depends on the winches. If the winches are still made, it might be cheaper to replace the drums. If you have a friend with a machine shop, might be faster and cheaper to have them re-surfaced.

If I replace them, I may extend the halyards back to the cockpit, but then how does one attach turning blocks , rope clutches and the new winches to the coachroof solidly enough to withstand the strain of the halyards.

You can add a collar to the mast step or cabin top that you can add turning blocks to, to lead the halyards back. You'll need to get several line clutches and organizers to lead the lines fair to the winches. The winches and clutches need to be mounted with backing plates, and the holes for the fasteners need to be properly potted if the deck is cored. Garhauer Marine is a good source for blocks and organizers, however, I'd recommend Lewmar line clutches, since they have consistently rated as the best with the least line wear in Practical Sailor Magazine's tests.

Then I have the problem of closing the holes on the mast left by removal of the old winches! Seems like every question leads to another question! Thanks for your advice.

If you can leave the winches on the mast, and use larger winches on the cabin top for the halyards left back, you'll probably be much happier. The additional friction from the turning blocks, line organizers and line clutches mean that what may have been sufficient at the mast, probably isn't going work very well at the cabin top. Also, the mast winches are going to be useful for the cunningham and many other things... so you should probably leave them there for that as well.