1984 Catalina 27 main traveler wood risers

[yelkenli]

I noticed that there is some daylight between my curved main traveler bar and the wood riser that it sits on, on the port side. And some of the flat head screws do not tighten, indicating they are stripped. The system held together this weekend in white cap winds, tacking and gybing, which is when I noticed it.

I would like to replace the wood blocks but cannot find a source. Catalina Direct sells a $1300 main traveler upgrade, which might be nice, but I don't want to spend that much.

Does anyone know of replacement wood risers?


The picture (not my boat, but same year and similar layout) here shows the wood risers on the main traveler ends.

 

[jssailem]

There is nothing special about those blocks. I would suggest you build your own. The cost from C D may be prohibitive. Perhaps you want them out of fiberglass. You could use the wood blocks as molds for a fiberglass cone.

 

[yelkenli]

Any pointers to how to do this would be great. I am handy, but like an example. My main questions is what would be strong enough for these forces - not sure what forces. If from wood, is a specific type needed - for strength and rot. What prep for rot?

I like the fiberglass option as it might minimize rot. Is there a method?

 

[jssailem]

Firstly, can you define the problem that you are experiencing with the present hardware? It may be that wood is the best solution.

Fiberglass would be feasible and could address rot is that is an issue. You will need to identify the issue of needed density and clarify how the part will be attached. Prototypes would be fairly easy to build once a design is identified. Fiberglass would be easy to shape. Part might be light in weight with the proper shape. Lots of shapes would be possible. The use of a wood or foam core would be viable.

 

[kloudie1]

I am not familiar with that particular traveler but it probably is thru-bolted to the cabin top with the wood serving only as a spacer. If the screws are stripped and the traveler did not come off, that is probably the case. Look for a way to tighten the thru-bolts .. loosen the screws that are in the wood then tighten the load carrying thru-bolts then retighten the wood screws?

 

[dlochner]

The forces on a traveller can be large, especially when jibing. As @kloudie1 says, they are probably through bolted. Look in the cabin for plugs or panels that can be removed, the nuts may be hiding behind them. I really doubt they are wood screws, although stranger things have happened.

If the traveller is just screwed into the wood, I would strongly consider replacing the wooden risers with metal and through bolting to the cabin top. Garhauer and others sell risers.

 

[dLj]

As others have said, it's highly likely the bolts are through bolts. How would you adhere that wood to the cabin top given the forces involved?

The underside should have some kind of backing plate/washer. If the original Installation does not, you may wish to consider changing that.

dj

 

[shemandr]

I would first look at the method of attachment of the traveler to the wood block before planing to replace the wood block. In the picture the detail is lost in a shadow.
If you want to replace the wood block I think you would need to laminate layers of whatever wood used together to get that thickness. I assume it would be hard and expensive to find hardwood of that thickness in a solid piece. This forum has posters with far better knowledge of wood than I and hopefully they'll chime in.
What is the existing wood?

 

[dLj]

I would first look at the method of attachment of the traveler to the wood block before planing to replace the wood block. In the picture the detail is lost in a shadow.
If you want to replace the wood block I think you would need to laminate layers of whatever wood used together to get that thickness. I assume it would be hard and expensive to find hardwood of that thickness in a solid piece. This forum has posters with far better knowledge of wood than I and hopefully they'll chime in.
What is the existing wood?

@shemandr you bring up a good point - you first have to figure out the current wood - especially the condition of that wood. It's very likely the current wood is fine - it does not need to be replaced. In the unlikely case that it is not through bolted, and the screws do actually go into the wood - you still don't necessarily need to change the wood. You can drill the existing holes oversized, fill with structural epoxy and then redrill for proper screw size and reseat the screws.

But @yelkenli has to figure out how this traveler is actually fastened and the condition of the wood.

dj