Advice on replacing standing rigging

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yelkenli

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Jul 7, 2024
9
Catalina 27 Lake Keowee
I am planning to replace the standing rigging on a new to me Catalina 27 that has lived on a lake for the last 40 years.

I do not know the age of the rigging. I don't see any corrosion. I only see that two of the wire ropes have slight kinks, one large enough for the strands to bird cage a tiny amount. I think this damage might be from stepping the mast.

I see a $950 set on Catalina Direct that includes the turn buckles, which I don't think need replacing. I think just the wire ropes need replacing.

Thoughts or advice?

Any recommendations on reputable rigging companies?
 
D

dlochner

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Jan 11, 2014
12,105
Sabre 362 113 Fair Haven, NY
I've used Rigging Only in Fairhaven, MA for my rigging and have been very pleased. I send the rigging to them and they duplicate it and send it back. Reasonable prices and good service.

Sailboat Rigging,Hardware & Accessories | Rigging Only's Online Store

Rigging Only is dedicated to providing quality sailboat hardware and sailboat rigging at affordable prices to sailors through out the world
www.riggingandhardware.com
 
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dLj

dLj

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Mar 23, 2017
3,721
Belliure 41 Back in the Chesapeake
yelkenli said:
I am planning to replace the standing rigging on a new to me Catalina 27 that has lived on a lake for the last 40 years.

I do not know the age of the rigging. I don't see any corrosion. I only see that two of the wire ropes have slight kinks, one large enough for the strands to bird cage a tiny amount. I think this damage might be from stepping the mast.

I see a $950 set on Catalina Direct that includes the turn buckles, which I don't think need replacing. I think just the wire ropes need replacing.

Thoughts or advice?

Any recommendations on reputable rigging companies?
Click to expand
Why skip the turnbuckles if you are going through this whole job? If it were my boat, I'd just replace the system...

dj
 
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Project_Mayhem

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Sep 24, 2018
2,934
O'Day 25 Chicago
yelkenli said:
I do not know the age of the rigging
Click to expand
Then it's time to replace the rigging. I just got a quote from a local rigger for my C30 for $2400. CD has everything for $1300. The rigger said he couldn't even come close to CDs price. Replace it all for that price. Metal fatigue is real. 40 years is a lot on anything mechanical
 
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jssailem

jssailem

SBO Weather and Forecasting Forum Jim & John
Oct 22, 2014
21,975
CAL 35 Cruiser #21 moored EVERETT WA
yelkenli said:
Thoughts or advice?
Click to expand
How long do you think you want to safely sail on your boat? Replace the rigging that will assure you that safe experience.
 
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Ward H

Ward H

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Nov 7, 2011
3,744
Catalina 30 Mk II Cedar Creek, Bayville NJ
@Project_Mayhem Did you miss something at CD for your rigging? I was curious about the large cost difference between CD and a rigger so I put together the items I'd need from CD for my C30 Tall Rig w/ bow sprit.

Pre-made shrouds and forestay w/ turn buckles $1366
Back stay and bridle w/ turn buckles $800
Bob Stay (bow sprit) $255
Total $2,421

Your rigger's price of $2,300 sounds pretty good. That's what I paid in 2018 to have my local rigger replace everything I listed, except the forestay. I did that in 2023 when I replaced the furler.
 
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Project_Mayhem

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Sep 24, 2018
2,934
O'Day 25 Chicago
Ward H said:
@Project_Mayhem Did you miss something at CD for your rigging? I was curious about the large cost difference between CD and a rigger so I put together the items I'd need from CD for my C30 Tall Rig w/ bow sprit.

Pre-made shrouds and forestay w/ turn buckles $1366
Back stay and bridle w/ turn buckles $800
Bob Stay (bow sprit) $255
Total $2,421

Your rigger's price of $2,300 sounds pretty good. That's what I paid in 2018 to have my local rigger replace everything I listed, except the forestay. I did that in 2023 when I replaced the furler.
Click to expand
Pre-made shrouds and forestay w/ turn buckles $1366 - Sounds about right
Back stay and bridle w/ turn buckles $800 - You're correct. I didn't realize the backstay wasn't included
Bob Stay (bow sprit) $255 - Mine is a standard rig so no bob stay I assume

No labor is included in any of the pricing I listed. @yelkenli replacing is easy if the mast is down and if it's up, doable with a bosuns chair and a second hand. A rigger can also do it
 
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Y

yelkenli

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Jul 7, 2024
9
Catalina 27 Lake Keowee
Thanks for the comments. My question is not if I should replace. I am replacing. Just looking for advice and input, and I got it.

Thanks!

My mast is down as I hauled it from another lake. Currently replacing an ever so loose cutlass bearing, mast lights, and bottom paint.
 
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Project_Mayhem

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Sep 24, 2018
2,934
O'Day 25 Chicago
yelkenli said:
Thanks for the comments. My question is not if I should replace. I am replacing. Just looking for advice and input, and I got it.

Thanks!

My mast is down as I hauled it from another lake. Currently replacing an ever so loose cutlass bearing, mast lights, and bottom paint.
Click to expand
You are dealing with nearly the same repairs as me. Updated total from Catalina Direct is 1700 vs 2400 from a local rigger
 
FastOlson

FastOlson

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Apr 8, 2010
2,021
Ericson Yachts Olson 34 28400 Portland OR
While the spar is down where you can work on it, it's past time to replace the wiring inside--- Coax and 12 volt. The old lighting fixtures are probably beyond their service life, too.
 
Y

yelkenli

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Jul 7, 2024
9
Catalina 27 Lake Keowee
@FastOlson I replaced the lights on the mast. I ohmed out the 12V wires and identified no problems. Replacing such old wiring is of interest, but for the radio antenna, there is minimal value as it is not really needed - I have a hand-held radio sufficient for my needs.

Do you know how the wiring is installed? The wires are in a tube in the mast, and they stop mid mast to pick up the nav/deck light. Is it secured there, and if so, how to I unsecure/resecure?
 
jssailem

jssailem

SBO Weather and Forecasting Forum Jim & John
Oct 22, 2014
21,975
CAL 35 Cruiser #21 moored EVERETT WA
Generally the tube is thin wall PVC attached to the mast using rivets. The wires are strain relieved at the mast head or mid-mast to provide power for spreader lights and hang in the tube.
 
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Ward H

Ward H

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Nov 7, 2011
3,744
Catalina 30 Mk II Cedar Creek, Bayville NJ
yelkenli said:
Do you know how the wiring is installed? The wires are in a tube in the mast, and they stop mid mast to pick up the nav/deck light. Is it secured there, and if so, how to I unsecure/resecure?
Click to expand
On my C30, at mid mast the tubing cut and pulled apart a few inches. The mid mast wires were pulled out of the mast at that point. They were not secured inside. They were knotted inside the light fixture.
 
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dLj

dLj

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Mar 23, 2017
3,721
Belliure 41 Back in the Chesapeake
yelkenli said:
Do you know how the wiring is installed? The wires are in a tube in the mast, and they stop mid mast to pick up the nav/deck light. Is it secured there, and if so, how to I unsecure/resecure?
Click to expand
It depends upon what kind of mast you have. There are a number of different ways this is done. A few years back, I redid the wiring in a mast where there was an extrusion that slid into tabs on the inside of the mast. The extrusion that held the wires was simply a slide into and out of the mast on these tabs. At the steaming light - mid mast - the wires simply came out of that extrusion and went to the mid-mast lights (it had a steaming light and deck flood). When rewiring, I ran a messenger line from the mast head and a messenger line from the hole in the mast for the mid-mast connections. Then slid the whole assembly in after replacing all wires. At the mast head, I don't remember what I did to keep the wires supported. I probably did a knot. At the mid-mast connection, I used a rubber grommet for chafe protection and a zip-tie for tension relief there.

You'll have to look inside your mast to see how your mast is assembled.

dj
 
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