Repairing lifeline connection

[hudson_rogue]

So I seem to have original coated lifelines on my 1980 Catalina 22.

They seem to be included enough shape for my upcoming season except this one location (see photos).

Do any of you have resources for repairing a line like this? I see stern line replacements available for sale online, but other than that just entire replacement kits which I don't need at this point.

Thanks!!!

 

[hudson_rogue]

This looks like the piece I need unless I can reuse the one I have with new lifeline wire.

LOOS Wire Rope Clevis Fitting: 1/8 in Compatible Rope Dia, Stainless Steel, Fork End

 

[hudson_rogue]

... also thinking of going with dyneema

 

[Captain Grey Beard]

I highly recommend you go with a synthetic line. Dyneema is a very good choice!
You don't need the super high quality stuff for a life line. That stuff is generally for standing rigging and applications that require tighter engineering controls. And the price reflects that.
A life line can use the budget stuff readily available on Amazon and other budget friendly sources. Look for synthetic winch line.
Plus the big advantage is it's user friendly when it comes to service and maintenance.
I always prefer the "Do it myself" options.

 

[Davidasailor26]

This looks like the piece I need unless I can reuse the one I have with new lifeline wire.

LOOS Wire Rope Clevis Fitting: 1/8 in Compatible Rope Dia, Stainless Steel, Fork End

Yes, that looks roughly like the right part. No, you won’t be able to reuse the existing one, because when it’s installed it gets permanently compressed around the wire. The bigger problem you’ll have is that to install an end like that you’ll need to cut all the bad/untwisted wire off, and then use a specialty swage tool to fasten the new end on. My guess is once you cut off the bad wire section you won’t have enough wire left to span the length of the boat. Even if you did, I probably wouldn’t trust the rest of that wire seeing how the end failed.

Dyneema is not a bad option. It’s definitely easier to DIY. Just be careful that there are no hard chafe spots like in the stanchions. If there are you’ll need to add thimbles to make sure the dyneema doesn’t get cut.

 

[Calif. Ted]

Take to your local rigging shop or take it to West Marine and tell them to make you a new one, they will send it to their nearest store with rigging services.

 

[Captain Grey Beard]

Yes, that looks roughly like the right part. No, you won’t be able to reuse the existing one, because when it’s installed it get permanently compressed around the wire. The bigger problem you’ll have is that to install an end like that you’ll need to cut all the bad/untwisted wire off, and then use a specialty swage tool to fasten the new end on. My guess is once you cut off the bad wire section you won’t have enough wire left to span the length of the boat. Even if you did, I probably wouldn’t trust the rest of that wire seeing how the end failed.

Dyneema is not a bad option. It’s definitely easier to DIY. Just be careful that there are no hard chafe spots like in the stanchions. If there are you’ll need to add thimbles to make sure the dyneema doesn’t get cut.

EXCELLENT POINT!
Yes! Debur EVERYTHING!
I'd use a single cutter counter sink tool to lightly chamfer both ends of the hole through each station.
And perhaps install a piece of adhesive lined heat shink at each stantion. Just as chafe protection and an early warning indicator to expose any chafing issues / spots.
I don't have life lines.... I'm far too clumsy for that.....they tend to do more to trip me than anything else....

 

[Gene Neill]

I would definitely replace the lifelines altogether.

Or, get rid of them altogether. I'm 100% on board with @Captain Grey Beard on that.

 

[hudson_rogue]

I like the dyneema idea but every example Or online looks very ad-hoc / messy. Maybe there is a middle ground combining dyneema and turnbuckles.

 

[fred1diver]

For Dynema, you could always do a whoopie sling to make the adjustments, then sew it where you like the final size and cut the tail, would look cleaner, or have the whoopie at the bow end and just tie off the tail to make it look nice to keep the adjustability.
Keep in mind that being adjustable would be better in the long run, would give you room to cut an end if needed!
Very easy to work with, very basic and cheap tools needed.

 

[Davidasailor26]

I like the dyneema idea but every example Or online looks very ad-hoc / messy. Maybe there is a middle ground combining dyneema and turnbuckles.

One end should be very easy to make neat and clean with a splice. For the other end either do the sling like Fred mentioned, or you could get a fitting like Tubular Turnbuckle with Splice end - LS-2900. (That’s just one example; there are quite a few types)

 

[dlochner]

I'm not a fan of dyneema lifelines, because in the long run I don't believe they are as economical as people want to believe they are.

Lifelines are pretty inexpensive to replace. There is no need to replace turnbuckles barrels unless they have been stripped or otherwise compromised. Use bare wire instead of vinyl coated, bare wire is cheaper and safer.

Take the life lines off, label them and send them to a rigger who can reproduce them in short order. A swaged stud will run about $15 and $15 to swage it onto the wire. ¼" 7x7 wire will run under $3 a foot.

I've used RiggingOnly.com to replace all the rigging and have been pleased with their work, speed, and price.

 

[...3TacksontheWater]

I'm not a fan of dyneema lifelines, because in the long run I don't believe they are as economical as people want to believe they are.

Lifelines are pretty inexpensive to replace. There is no need to replace turnbuckles barrels unless they have been stripped or otherwise compromised. Use bare wire instead of vinyl coated, bare wire is cheaper and safer.

Take the life lines off, label them and send them to a rigger who can reproduce them in short order. A swaged stud will run about $15 and $15 to swage it onto the wire. ¼" 7x7 wire will run under $3 a foot.

I've used RiggingOnly.com to replace all the rigging and have been pleased with their work, speed, and price.

To my knowledge, Catalina did not go to open body turnbuckles until the new design. That in itself is a compelling reason to fully replace the life lines.

George

 

[hudson_rogue]

To my knowledge, Catalina did not go to open body turnbuckles until the new design. That in itself is a compelling reason to fully replace the life lines.

George

Can you explain what you mean by this? I'm trying to figure out if I should replace all my lifelines or just the one that is fraying. I'm on the fence regarding new dyneema lifelines or just sending in my steel ones to get rebuilt. I'm leaning toward the latter as long as the $ is about the same. ~$300 for dyneema lifeline setup and then I have to put it all together! Getting a quote from riggingonly and then I'll go from there. Not urgent as I'll be keeping the boat dry until next spring.

 

[...3TacksontheWater]

Turnbuckles come in several flavors. A closed body turnbuckle only lets you see the thread of exposed part of the toggle bolt. An open body turnbuckle lets you see the treads of the of the toggle bolt on both sides of the female so you can easily check for corrosion:

Turnbuckles

Catalina Direct, publishers of the Catalina 22 and Catalina 25 Owner's Handbooks and the largest supplier of parts and Lewmar winches for Catalina Yachts in the country

www.catalinadirect.com

George

 

[Project_Mayhem]

Closed body turnbuckles look nicer IMO but are a pain to work with. They often end up scratched around the hole used to tighten them

 

[dlochner]

Closed body turnbuckles can trap moisture which is not good for the SS stud.

Closed Body Turnbuckle:

Open body turnbuckle:

 

[Stu Jackson]

I'm on the fence regarding new dyneema lifelines or just sending in my steel ones to get rebuilt.

Why would you ever choose dyneema? It has a short shelf life compared to uncoated steel lifelines. Let's see: I have a choice between something that I'd have to replace in 5 to ten years compared to something that will last, essentially, forever. Golly, which one would I choose?

 

[fred1diver]

We replaced our lifelines with uncoated SS wires about 2 years ago, works very well, downside is that I asked my local chandlery to replicate what we had, worked well, but we hated the gates, so we had the lines cut and we made the gates out of dyneema, we do love it, but kind of wish we went with bigger size, maybe next season or over winter as a watching TV project?
To do it again? Probably all wire, but with the gates oriented differently, but having said that, we do love the suppleness of the dyneema gates.
Your boat your choice, just my .02 cents

 

[shemandr]

There is a liability issue to consider. If your life lines are professionally duplicated the company carries insurance and in the event of an accident with injuries their insurance would be involved. If one does it on their own I can image the line of questioning in a legal proceeding. "How many lifelines have you replaced? Where were you trained? Did you have your work inspected by a professional? Etc.
I don't like doing things to cover me from legal risk. But sometimes you have to consider risk management. In the book Atlantic High WFB details a legal case against him when someone drowned after falling off his boat due to lifeline failure. If I recall correctly the installer of the life line system ended up with the lump of coal.