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Old 04-08-2019, 21:43   #1
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Forestay Clevis Pin Situation

I do not know what to do with this standing rigging issue and looking for some advice. This is the clevis pin that attaches the forestay to the chainplate. The clevis pin is correctly sized for the chainplate, however, it is too small for the toggle underneath the roller furler. Should I drill a larger hole in the chainplate to remedy this? Attached are pictures of the issue. As you can see there is a washer on one side of the toggle, but the PO didn't put one on the other side.
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Old 05-08-2019, 01:00   #2
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Re: Forestay Clevis Pin Situation

That toggle looks far too lightweight for the job. Look at the thickness compared with what it’s attached to. Looks like an emergency substitution to me, I’d replace it with something much more substantial and take the opportunity to get the holes right.
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Old 05-08-2019, 01:36   #3
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Re: Forestay Clevis Pin Situation

Good catch, Grant! Take a moment to pat yourself on the back for your diligence.

I will echo what Tillsbury says, though: that looks w-a-a-a-y too insubstantial for the job it's doing. If it were me, I would get a professional rigger in there to offer advice on the correct fix. If you drill the chainplate as you suggest, would that ultimately weaken the fitting over time to the point of failure...?

As I don't know the answer to that, I'd want to get a definitive answer from someone who does.

Good luck!
Warmly,
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Old 05-08-2019, 03:35   #4
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Re: Forestay Clevis Pin Situation

Personally, I wouldn't use split rings either, but a proper cotter pin.

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Old 05-08-2019, 06:04   #5
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Forestay Clevis Pin Situation

Looks to me like there is plenty of meat to drill. However Id not do anything until after I had a pro rigger look at it, cause it came from the factory with something that fit that hole that was correctly sized.
If you drill, drill underside and ream to correct size, that leaves a smooth hole and eliminates any stress risers. Probably overkill as most things on a boat are way oversized anyway, but why not do it right.
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Old 05-08-2019, 09:14   #6
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Re: Forestay Clevis Pin Situation

Find a new beefier toggle that has the correct size pin holes. This may take time, if so, consider sleeping the undersized pin to fit. This should only be a short term solution, used u til you source the correct toggle.
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Old 05-08-2019, 20:39   #7
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Re: Forestay Clevis Pin Situation

As a rigger, i agree the toggle looks on the thin side, the clevis should have a cotter pin, not a ring, to answer the question, a rigging bushing can be used to bush up the hole on the toggle, they are made out of stainless steel.
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Old 05-08-2019, 23:20   #8
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Re: Forestay Clevis Pin Situation

You could TIG weld a couple of SS washers onto the insides and outsides of the toggle but I don't like welding onto stainless which appears to be already of limited capacity.
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Old 05-08-2019, 23:42   #9
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Re: Forestay Clevis Pin Situation

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Originally Posted by Dougtiff View Post
.... a rigging bushing can be used to bush up the hole on the toggle, they are made out of stainless steel.
The bush can be made fairly simply by getting the correct sized clevis pin for the toggle, drill the centre out to the size of the smaller clevis pin, cut it to make two bushes and use these bushes to fit into the toggle cheeks. The smaller clevis pin will now fir both the tang and the toggle. Finish off with a cotter pin.
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Old 06-08-2019, 10:21   #10
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Re: Forestay Clevis Pin Situation

I don't have access to a metal lathe where I am, so building a bushing is going to be difficult for me. Is drilling the chainplate not a good idea? to just have a larger clevis pin through the whole setup. Or should I try to find a different toggle? Does anyone have pictures of the bushing suggestion or a website where I could find an example of one?
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Old 06-08-2019, 10:38   #11
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Re: Forestay Clevis Pin Situation

Bushings should be pretty widely available, probably in bronze, which ought to be fine I think. Even Auto parts stores ought to have a stock of bushings. I think bushing is better than drilling as its not permanent and is easily undone.
Biggest issue with drilling is ensuring there is enough meat in the chain plate, you want at least as much metal left around the hole as the size of the hole. Plus of course if drilled, you cant go back, and the boat was built with the smaller hole, so in my opinion you ought to go back with whatever the stock solution was.
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Old 06-08-2019, 11:20   #12
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Re: Forestay Clevis Pin Situation

You can bush with s.s. tubing or yello mental, i would not drill out the chain plate.
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Old 06-08-2019, 11:48   #13
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Re: Forestay Clevis Pin Situation

All of these are temporary fixes though. As soon as you can get a proper toggle and the right fittings if you like your mast pointing upwards.
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Old 06-08-2019, 12:07   #14
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Re: Forestay Clevis Pin Situation

Have a local rigger get you the correct toggle and clevis pin, that will be the most direct way to take care of the issue.

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Old 06-08-2019, 12:51   #15
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Re: Forestay Clevis Pin Situation

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Originally Posted by Sailor_Grant View Post
I don't have access to a metal lathe where I am, so building a bushing is going to be difficult for me. Is drilling the chainplate not a good idea? to just have a larger clevis pin through the whole setup. Or should I try to find a different toggle? Does anyone have pictures of the bushing suggestion or a website where I could find an example of one?
Drilling or reaming the hole in the chain plate is a viable solution provided that the portion of the circumference towards the end of the chain plate is not excessively reduced in thickness. It would be a miserable job but filing the hole out in the direction away from end of the chain plate would serve without thinning the subject section of the circumference.
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