Bolt inside Schaefer roller furler snapped

[coreyjohnson99]

While sailing our 1979 Newport 28 and 115% genoa, the bolt inside of the furling drum snapped. Somewhat of a hectic situation with genoa flapping all over while trying to get it down, but managed to save the sail and drum hardware from the drink. I assume the roller is original to the boat. The roller furler has no extrusions and our genoa has a wire inside. I took the drum assembly apart which had the bolt and bearings around it.

First two pictures are the drum assembly with the broken bolt towards the bottom.
Third picture shows drum getting disassembled.
Fourth pic = top of genoa (rides up the forstay)
Firth pic - bottom of genoa
Sixth pic - shows where the other part of bolt screwed into nut. It also has a pin that went through the bolt and nut, this was the point of failure.
The rest are of the bolt after it being removed from drum.
Any ideas on a fix / replacement? Thank you all!

 

[dlochner]

Have you called Schaeffer? They might have some parts laying around.

More than likely your are looking at new furler. How is the forestay?

 

[Leeward Rail]

Worst case a machine shop could likely make that bolt. Less hassle that a new furler assuming that the rest is serviceable.

 

[capta]

The idea of replacing an old furler with a new one might sound appealing until you consider that you must get the sail (s) refitted for a foil system. However, you must take into account how long you intend to keep the boat and how much the boat is worth on resale.
I'm wondering how you could tighten that bolt with a round head and I'd guess it was pressed in there. You might wish to make friends with a machine shop.

 

[coreyjohnson99]

Thank you for the suggestions. I'll get in touch with Schaeffer during the business week and go from there. Also will try to get in touch with a machine shop.

 

[kloudie1]

Yup, a machine shop can make the bolt/axle .. If you can spring for Titanium, the harder axle would stop some of the galling wear that you can see on the surface. That axle used to be cylindrical. If I read it right, the pin/axle slips through the rotating part of the drum and slips through the fixed bottom plate. The nut is snugged up so that the drum turns freely but not loosely, then the lock pin goes through and the set screw is tightened to set the line guide in the correct direction..
Buy Titanium Round Bar Online (onlinemetals.com)

 

[RitSim]

This should be easy for a machine shop to duplicate. However, I would consider a set screw with the bolt drilled slightly for a dimple under the set screw as an improvement to the bolt area. The set screw would have to be checked as it may come loose.

 

[dLj]

Yup, a machine shop can make the bolt/axle .. If you can spring for Titanium, the harder axle would stop some of the galling wear that you can see on the surface. That axle used to be cylindrical. If I read it right, the pin/axle slips through the rotating part of the drum and slips through the fixed bottom plate. The nut is snugged up so that the drum turns freely but not loosely, then the lock pin goes through and the set screw is tightened to set the line guide in the correct direction..
Buy Titanium Round Bar Online (onlinemetals.com)

With all due respect - this part would be a very bad choice to use titanium. Grade 2 is not strong enough and Ti6Al4V is too notch sensitive for an application like this.

dj