Haylard "traveler" on very old Flexible Furler - replacement or rig?

[flyingwaspsailing]

Hi - I went to replace the halyard on my older flexible furler and was confronted with a haylard design that uses a slug that fits into the extruded luff shaft. The issue is that there is no way to place another line into the slug (it looks like it may actually be called a traveler in looking at parts on CDI's website - CDI FF9 Halyard 5/32 wire 53' with traveler).

I'm usually pretty creative on improvising but decided to just leave it alone until I figured something out.

Please take a look at the pics and let me know your thoughts about this.

 

[flyingwaspsailing]

I just came across this: CDI #1933 FF4 Halyard Assembly - Marine Outfitters

Which references
CDI #1933 FF4 Halyard Assembly
Part #1933. 37' 1/4" polyester yacht braid with ferrule. (Old part #1997 3/16 rope halyard with molded-on black plastic traveller has been replaced by part # 1933. The new halyard #1933) uses a 1/4" rope with a stainless steel ferrule swaged on)

At $160 for a 3/16" double braided rope with a SS ferrule swaged on is outrageous.

Any thoughts? Much appreciated!

 

[Tally Ho]

So the rope in the traveller cannot be pulled from the end (pulling the rope out of the molded plastic)?

What does the new halyard come with…a furrule? How does that attach to the sail?

My old CDI has a metal halyard and a metal traveller. But it is on an O’Day 322.


Greg

 

[Timm R Oday25]

I ran into the exact same problem last summer . I work in a very large machine shop . After making quite a few that almost good enough ,I finally decided the last one was good enough . I have a few I could send you .
The funny part came a few days later when I was showing my part to a friend .
His 20 year old son looked at the part I labored for days making just right and told me that he could have
made the part in 30 minutes with his 3D printer .
I'm not sure where you located ,I'm willing to bet you know some young person
who willing to show off his new 3d skills

 

[garymalmgren]

Is the line glued into the traveler of somehow hot molded?
Maybe cut it off, drill out and reglue.
Even if you make a new traveler up you have to attach the line securely so it doesn't pull out.

gary

 

[flyingwaspsailing]

Hey thanks everyone -

So the rope in the traveller cannot be pulled from the end (pulling the rope out of the molded plastic)?

What does the new halyard come with…a furrule? How does that attach to the sail?

My old CDI has a metal halyard and a metal traveller. But it is on an O’Day 322.


Greg

Hi Greg - Yes, that seems to be the case - i.e. you need the plastic traveler inserted in the extruded housing to pull the haylard down (which runs up through the top of the furling) to raise the sail. It's a pretty simple design. Seems that the metal ones are how they are doing it today. Thanks!

 

[flyingwaspsailing]

Is the line glued into the traveler of somehow hot molded?
Maybe cut it off, drill out and reglue.
Even if you make a new traveler up you have to attach the line securely so it doesn't pull out.

gary

Thanks Gary - it looks hot molded to me but perhaps the drill out method will work. Will consider it. Thank you!

 

[flyingwaspsailing]

I ran into the exact same problem last summer . I work in a very large machine shop . After making quite a few that almost good enough ,I finally decided the last one was good enough . I have a few I could send you .
The funny part came a few days later when I was showing my part to a friend .
His 20 year old son looked at the part I labored for days making just right and told me that he could have
made the part in 30 minutes with his 3D printer .
I'm not sure where you located ,I'm willing to bet you know some young person
who willing to show off his new 3d skills

Hey Timm - Thanks for the feedback. I think I may have access to a 3d printer so may consider that route. Thanks for the offer to share one of your metal ones. I'd be glad to pay you for the shipping and something for the traveler if you don't mind sending one to me. My email is flyingwaspsailing@Gmail.com so that we can connect.

- Glenn

 

[flyingwaspsailing]

Hi - I went to replace the halyard on my older flexible furler and was confronted with a haylard design that uses a slug that fits into the extruded luff shaft. The issue is that there is no way to place another line into the slug (it looks like it may actually be called a traveler in looking at parts on CDI's website - CDI FF9 Halyard 5/32 wire 53' with traveler).

I'm usually pretty creative on improvising but decided to just leave it alone until I figured something out.

Please take a look at the pics and let me know your thoughts about this.

UPDATE: I got a response from CDI and here it is:

" Looks like you need a new Halyard Assembly

Halyard Assembly - CDI Furlers

You just need to determine what furler you have.

Identifying Your CDI Flexible Furler - CDI Furlers

Ron
CDIFurlers.com"

It's not really clear what the new part looks like but it seems that they're no longer using the traveler design that I have in the photo but rather it's a furling that is swayged onto the haylard and the line just exits the luff extrusion.

Here are some photos I dug up showing the sawge style. Can't seem to find a 1/4 round swage online...

 

[Timm R Oday25]

Feeding the number 6 sail tape up the slot proved to be the most difficult part . Copious quanities of teflon is your friend , sail coat ?

 

[kappykaplan]

sail coat

McLube Sailkote Dry Lubricant - use it every year when I put the jib on its furler

 

[flyingwaspsailing]

McLube Sailkote Dry Lubricant - use it every year when I put the jib on its furler

Yeah, that's the route I took and it was ok but man you really have to hank down on the haylard and push the sail up into the slot to reduce the weight of it.

 

[DrJudyB]

Street price is around $115 online.

CDI FF4 Halyard

CDI FF4 Furler Halyard Assembly, 1/4" x 37' with Ferrule

www.velasailingsupply.com

Judy Blumhorst
Owner, CDI
www.SailCDI.com