I recently got some Samson MLX3 line to make new halyards with. This is a moderately high-tech core-dependant double braid line. It has a polyester cover and an HMPE - MFP blend core and requires a Class 2 splice. For use in a halyard, should I install a thimble and if so, which kind.
For all of my halyards, I use Dyneema soft shackles.
I see them in stamped SS, cast SS, nylon. Given that they will be connected to soft shackles, do I need a thimble or just the bare polyester cover?
A nylon thimble will collapse under any real load. I feel like they are mostly cosmetic.
Never stamped SS with rope. They are for wire cable and the ends can damamge the rope if they shift, and they often do, because ropes stretch under load and Dyneema splices loosen as they set. Starzinger posted an image of a JSD bridle nearly cut through by a wire rope (stamped) thimble that shifted. Not worth the risk. Sailmaker's and cast thimbles will work, but you don't need them.
My preference, if there is not a terrible d/D ratio problem, (1:1 is OK for eye splices in Dyneema according to the makers) and no very sharp edges, is a webbing thimble. Just hot cut a length of tubular webbing (like climbers use) over a mandrel (to avoid sealing the ends together) and thread it on. Or Dyneema chafe sleeve (although it is actually no more chafe resistant than nylon climbing webbing, only more compact, which is not a benefit in this case--tested). Or no thimble.
Normally halyard chafe is the result of the splice and shackle hitting the masthead and creating burs, which the rope then rubs against. Balls before the splice prevent this.