1. What is the best way to attach a bail to the boom? (bolt, rivet, etc.)
2. Will drilling bolt holes in the boom decrease structural integrity?
3. Can I also use a bail on the mast or do i need some sort of bracket?
4. The vang should be set at about a 45 deg. angle, correct?
Thank you, any advise is appreciated![/QUOTE]
1) I recently installed a boomvang (solid) and used 1/4" S/S rivets. I expect them to be stronger than a threaded joint in thin metal.
With a rivet, failure is when either the rivet snaps or the rivet rips the hole out. With a bolt in thin metal, it's when the threads shear.
It's interesting to go and look how the boat builder attached things to the mast and boom. How does the boom attach to the mast for example? Stainless rivets. Maybe they knew what they were doing?
You'll probably need need 1/4" rivets and an ordinary riveter won't cut it. You'll need something like this :
Amazon.com: Astro Pneumatic 1426 1/4-Inch Heavy-Duty Hand Riveter: Home Improvement
2) Yes, but so little it doesn't matter. There are already plenty of holes in the boom and mast where things are attached so two more won't make any real difference.
In case you want to go down that route, Garhauer sell solid boomvangs where they custom make the boom and mast brackets.