To close out this thread. I replaced the outhaul line by suspending the boom with the topping lift and with the main halyard wrapped around the boom. I then drilled out the rivets holding the forward casting (end cap) and replaced the line. I had to do it this way since the outhaul line was terminated on the block that was "captive" in the forward portion of the boom so could not reach it without taking the forward casting off. On the recommendation of US Spars (David there was great) I oversized the holes, threaded the boom and casting and used 5/16 -28 machine screws to reattach the casting to the boom Here are pictures showing the end cap with the rivets drilled out, the interior of the boom with the forward block and a rough sketch of the line arrangement. Hope that helps others if faced with this. If they simply had terminated the outhaul line on the block at the aft end of the boom this could have all been done by just pulling that block out the end of the boom (it will pull out). When I posited this to Dave he sail "French engineering" with Z-Spars.
Last edited:
