45 yr old mast with internal wire halyards

[jeanathon]

Thoughts based on the photos?

[boatman61]

Get the grooves filled and smoothed and switch to rope...

[kentobin]

I agree with the rope recommendation but make sure your masthead sheave is the correct size for the rope diameter you use.

[Cheechako]

Originally Posted by boatman61

Get the grooves filled and smoothed and switch to rope...

another vote. If you stay with wire, I would modify the mast to eliminate the wear area entirely. cut it out and radius/smooth the exit area.
But soft halyards are the way to go for sure.... winch costs being the issue I suppose.

[Celestialsailor]

The upper sheave seems like it is too small a diameter. The wire should clear the exit of the mast head. Replace the S.S. exit plate with a new one. It is meant to be sacrificial. wire brush and acetone the grooves, fill with epoxy/mill fibers and cabosil and viola. Personally I like wire because there is no stretch and weather well.

[gjordan]

If you dont want to replace the exit plates, get some SS half round and screw it so that the wire runs across it rather than wearing on the mast. Cut and drill a few extra pieces so that you can replace them every 2 or 3 years. It might be worth a try. ____Grant.

[jeanathon]

Thank you all.
You affirmed what I was thinking. Namely weld and fill the areas that are worn, and put something sacrificial to hold the wire off the aluminum. Might be a bit tricky on the inside of the mast, but doable.
Nostrovia!,
Jon

[Celestialsailor]

Originally Posted by gjordan

If you dont want to replace the exit plates, get some SS half round and screw it so that the wire runs across it rather than wearing on the mast. Cut and drill a few extra pieces so that you can replace them every 2 or 3 years. It might be worth a try. ____Grant.

Have you actually tried that or just an idea? I think it might cause the wire to jump sid to side. Why not do it right and just make a new plate?
Also...I would not weld on the mast. When spars are extruded, the have a temper built into them. When you weld, often tines the temper goes away.

[gjordan]

I have seen it done on other boats. I have not done it myself, but would consider it before I would use epoxy or welding. I have also seen resone(sp?) phenolic blocks used to prevent that kind of gouging in masts or booms. There is often more than one way to skin a cat. _____Grant.

[jeanathon]

Got it. No welding. It is hard for me to comprehend epoxy being of a structural benefit here, or is it just for looks?

[Celestialsailor]

I was suggesting epoxy for the grove at the top and yes looks only. Like I said earlier, I think the sheave diameter is too small. A larger diameter would allow the wire to exit further away from the spar.

[JPA Cate]

We've been using low-stretch line for years, having ruthlessly eliminated wire halyards. Stretch has not been a problem with kevlar or spectra halyards, although the spectra creeps a bit, and we sometimes need to re-tension the main halyard. I feel entirely satisfied with them, and glad to lose the source of "meathooks." FWIW

Ann