HELP! with outhaul line replacement

[smokey73]

1994 Hunter 40.5. I started to replace the outhaul line on my 40.5, which is looking pretty ratty. The line runs inside the boom and has a set of blocks to increase the purchase but I can't figure out how to replace it. It looks the termination point of the line is on one of the blocks that is fixed inside of the boom rather than the block that can be pulled out the aft end of the boom. Why on earth you'd design it such that you have to remove the boom and the ends to replace this line is beyond me as an engineer. Below is a crude sketch. Does anyone have experience with replacing this line and can it be done without removing the boom and the forward cap.

 

[stickinthemud57]

Trained rat?

Sorry for being facetious. I really did give it some thought, but it looks like major surgery is the only solution.

 

[Rick D]

1994 Hunter 40.5. I started to replace the outhaul line on my 40.5, which is looking pretty ratty. The line runs inside the boom and has a set of blocks to increase the purchase but I can't figure out how to replace it. It looks the termination point of the line is on one of the blocks that is fixed inside of the boom rather than the block that can be pulled out the aft end of the boom. Why on earth you'd design it such that you have to remove the boom and the ends to replace this line is beyond me as an engineer. Below is a crude sketch. Does anyone have experience with replacing this line and can it be done without removing the boom and the forward cap.

View attachment 227860

I'm pretty sure I did that, but having owned the boat for 25 years, I sure don't remember how... What about a splice into a good section???

 

[jssailem]

Smokie. When I had my mast refitted, the boom was included. Like you, I have a block-and-tackle arrangement in the boom. Both ends of the boom were removed to replace the outhaul line.

 

[smokey73]

I fear you are right @jssailem. I don't race, so for the time being I'll secure the outhaul line at a fixed length and live with that until I can get a chance to take the boom off. I could have easily designed the block and tackle system so that you wouldn't have to remove the the boom end caps to replace the line by simply having the line tied off to the block that can be removed from the aft or "free end" of the boom rather than tying it off on the forward fixed

 

[BAD ORCA]

Mine is the same as are probably most of our boats. I took my boom off completely and both ends as well. There would be absolutely no way to change mine without taking the end of the boom off. Its a pretty robust and protected arrangement. I'm guessing most builders figured many of their boats would probably not survive long enough for a replacement to become necessary. I'm leaving my 40 year old blocks and lines alone. Im just going to lubricate the block with dry lube and call it a day. I hardly ever use the outhaul anyways.

In order to get mine out i would have to remove one of my boom bails from the boom to get the entire assembly out. The hard part would be getting the inner block back on the bolt four feet inside the boom and lining up the bolt holes. It looked daunting enough even with the boom ends off to decide to put it off for a few more years. I wish i had more useful advice.

 

[smokey73]

Even with the end caps off I am not sure how the block that is apparently attached at the mast end of the boom. Does anyone know and with the end cap off can you reach it? I guess so since they had to install it.

If we have a hurricane coming for a direct hit I'll probably remove the boom as part of my preparations. It is just about as easy to remove the boom as it is to remove the mainsail and stackpak. When I do that I'll tackle replacing the outhaul line. If we don't have a hurricane and I'll find a time when I have the inclination to "fix something." I "pleasure sail" only and often solo, so I seldom, if ever, adjust the outhaul.

I'll cross the bridge with reaching the block when I get to it. Being out sailing is more important than squeezing every last bit of speed out of it. I realize that not having the ability to adjust the outhaul will limit my sail trim for the wind speeds so I'll set it for moderate wind since I don't go out in heavy winds normally.

 

[BAD ORCA]

Even with the end caps off I am not sure how the block that is apparently attached at the mast end of the boom. Does anyone know and with the end cap off can you reach it? I guess so since they had to install it.

If we have a hurricane coming for a direct hit I'll probably remove the boom as part of my preparations. It is just about as easy to remove the boom as it is to remove the mainsail and stackpak. When I do that I'll tackle replacing the outhaul line. If we don't have a hurricane and I'll find a time when I have the inclination to "fix something." I "pleasure sail" only and often solo, so I seldom, if ever, adjust the outhaul.

I'll cross the bridge with reaching the block when I get to it. Being out sailing is more important than squeezing every last bit of speed out of it. I realize that not having the ability to adjust the outhaul will limit my sail trim for the wind speeds so I'll set it for moderate wind since I don't go out in heavy winds normally.

Do you have a boom bail or a bolt going through the mast in the approx. location of the hard to reach block? I have a boom bail as previously mentioned thats attached with a bolt that goes right through the boom completely. Maybe they riveted in a metal post if not?

 

[shemandr]

Did this or something like it on my Ranger 29. Different boat of course. I agree the mast boom end has to come off and the boom needs to be set up to work on - like on saw horses. The block on the mast end needs to come out of the boom. It is attached to the boom in some way: Rivets, machine screws or, God forbid, bolts. Rivets get drilled out, machine screws backed out (Unless corrosion prevents) and bolts ... Hopefully not the case.
As long as the tail is long enough, you pull that whole block out of the mast end of the boom. The block that is in the aft end of the boom has to travel forward so that you can pull the mast end one out. So you have to rig a messenger line to either the block or the shackle that attaches to the sail.
Once the mast end block is out of the boom, it will be fairly easy to untie the knot. attach the new line to the old line (Cutting the line past the knot which will not go around the blocks easily), and reeve the new line through the blocks and eventually out the mast side of the boom. Tie the new line to that block. Once that is accomplished you can use the messenger line on the sail shackle or aft block to pull the mast side block back into the boom.
You then have to reattach that block to the boom. No one says it has to be in the same location. So pick a spot you can reach with your hand or some implement. Reattach the boom end.
That is how I would approach it based on my understanding of your drawing. It is possible that the mast side block is on a pendant, which would make it easier.
If your reefing lines are also in the boom caution is needed to not tangle them. Reeving a new line using the old on should prevent entanglements.
For me having the sail deepen in gusts was annoying. This would induce more heel, load up the rudder, increase weather helm and ultimately slow the boat. With a proper tight, very low stretch outhaul in a gust the boat will dip its shoulder and come up with acceleration - big difference. I changed the outhaul line on my H356 (With in mast furling) for the same reason and even better results. I don't regard this improvement as trivial.

 

[LloydB]

not sure I would care if the standing loop between the forward and aft pully looked ratty or not but i would want the loop to never break. it looks to me that you could pull out 120% of the standing loop and replace it without worry with well made equal or stronger line after inspection and replacement since the standing loop length never changes.

 

[smokey73]

@shemandr Thanks for the detailed response. That was excellent info and advice. I had pulled out the boom end block and realized that the outhaul line was not dead ended on that block. If they had just dead ended the line at the boom end block then it would be a simple task to use the existing line to pull a new line since you can pull that block out of the end of the boom.

 

[jssailem]

If they had just dead ended the line at the boom end block then it would be a simple task to use the existing line to pull a new line since you can pull that block out of the end of the boom.

That is the way it should be. But. By making the dead end on the mast end they get an additional purchase on the rig when leading the line forward to the mast. Guessing here, because the size of the blocks are limited (being inside the boom) and accessing them is a rare occurrence, they opted to get the extra purchase while spreading the load on the line over more surface.

It was a compromise decision. Fortunately it will be a onetime thing project during your ownership.

 

[shemandr]

Since the outhaul line exits the boom at the mast end of the boom, and likely runs down to a turning block on the deck, is it possible to run it through a stopper and then to a winch? Then the line in the boom could be simple (Without turning blocks or purchase) and the winch would provide the power.

 

[Calif. Ted]

My rigging plan looked like yours with the bitter end at the fixed block, when I discovered the moving block was broken. I temporarily used an extra reefing line for an outhaul until I had parts, time and motivation. On removing block from aft end I was pleasantly surprised to find the line terminated on the block so I was able to change out line and block without ANY disassembly. A rare boat chore that turned out easier than expected.
I don't know if it came that way from the factory, the original owner made some changes to boom hardware, added reef hooks to gooseneck and changed the reefing plan.

 

[jssailem]

made some changes to boom hardware, added reef hooks to gooseneck and changed the reefing plan.

I made those same changes when I had the boom off on my boat. After 42 years refitting is needed. New ideas are discovered that improve on original construction.

 

[Scott T-Bird]

I can't imagine why anybody would settle for a static clew position - racing or not. Draft is a critical adjustment to make even casual sailing comfortable. That said, it's a good time to maintain or replace the blocks anyway. So you may as well get off your a$$, quit griping about the complexity, and get after it! Sure, you'll have to take off both ends ... so what? You just said you could design a better way, so what's stopping you? (I just thought you might like a slice of motivation )

 

[Ward H]

My C30 had a bit complicated system for the outhaul that was internal to the boom. It failed, I tried fixing it and it failed again.
I took it out and put blocks at the clew for a 3-1 purchase and again where it came out of the boom and went down to the deck. There I added another 3-1 purchase. Now I just have to be careful about too much force and ripping the sail.

 

[jssailem]

Too much of a good thing?
Did not expect that possible.

 

[Rick Webb]

Why on earth you'd design it such that you have to remove the boom and the ends to replace this line is beyond me as an engineer

I could have sworn engineers were taught to do that crap on purpose.

Glad to hear it is not the entire crowd.

 

[smokey73]

I could have sworn engineers were taught to do that crap on purpose.

Glad to hear it is not the entire crowd.

Yea, my Dad was a "boot strap" engineer (non-degreed) who spent his career tweaking the things that the engineers at a Navy missile design facility put on paper that might be technically okay but wouldn't work in a real life application or were to fragile to survive a launch from jet aircraft. He was a key player in the design of the "sidewinder" air-to-air missile and the "walleye" guided bomb (a pre-curser to our smart bombs today.) He was often their Tech-Rep when they tested them at White Sands. He taught me to look past the "book" and ask if I'd want it that way if I had to use it, maintain it, or fix it. When I was very young, (I'm 73 now) he took me down to their facility one evening and showed me a contraption on a small dolly with servo motors. He turned it on and then went to the other end of a hanger and lit a cigarette. He walked around the end of the hanger and the contraption homed in on him and followed him like a puppy dog. Turns out it was the guidance system for the soon to be "sidewinder" missile. Inspired me to be an engineer and to join the Navy.