I've looked at the pics again on my Mac and it looks like ... a mess. That re-enforces my opinion of starting over. I can't follow all the lines without excessive back and forth between the photos. But some issues I see are:
1) The tack of the mainsail is too far away from the mast. I don't know why you need two shackles there.
2) The line that exits the boom forward out of the forward boom cap/gooseneck is led thru a hole that is way too small. There will be chafe and the line will not run without excess friction. You need an exit block for that. Something like one of these:
West Marine
www.westmarine.com
3) The same line runs thru one of the shackles for the tack. It should not. Again the lead isn't fair and will have too much friction. It should go directly to a turning block (Type of which depends on where you want the line to terminate.).
4) Image 10 shows that same line going thru the shackle for the vang. It should not. That line needs to leave the boom with an exit block or plate, go to a turning block and then to another block on the deck that will direct it to a terminus.
5) I'm not sure the sail is on correctly. The re-enforcement of the cringle at the mast looks like what is done at the leech. Is the sail on backwards?
6) What is the timber across the companionway for? Is it temporary?
7) For the aft end of the boom I can't follow all the lines. But again the one running thru the pad eye on the bottom of the boom should not and it shouldn't be necessary to loop around the outhaul and boom to hold the sail closer to the boom. Those line will saw thru each other in short order. The outhaul properly run is the answer for that.
8) On the port side there is not a deck organizer on the deck as there is on the right side. I would install one for your jib halyard and what ever other lines may be used (Reef lines)?
9) At the base of the mast the most aft line (Main halyard?) seems ok but the next line up is coming out around that block in an unfair direction. So whatever that line is it will have too much friction and will chafe. The next line (Most forward) can't be led anywhere except athwartship unless it goes to a turning block of some sort. What is that line for. It looks a little like a messenger to me.
10) In image 2 there is a standing block forward of the vang with a line running thru it but I can't tell where the line originates or terminates. That's a nice block but it needs to be put to good use.
I hope this is helpful and not taken as critical. You just need to de-rig and start over.
Thank you for all the detailed analysis and advice! I'm working on this now, but wanted to reply to what I can at this time in case that changes any of the advice:
1) The tack of the mainsail is too far away from the mast. I don't know why you need two shackles there.
Is this good now?
2) The line that exits the boom forward out of the forward boom cap/gooseneck is led thru a hole that is way too small. There will be chafe and the line will not run without excess friction. You need an exit block for that. Something like one of these:
West Marine
www.westmarine.com
That is the reef line, a 3/8" as specified in the manual. I think it was supposed to be going down through that boom cap, not up through the hole, although the manual appears to show it going up through the small hole, then through a block, then back down again? Here is the manual:
I took it out of that hole and ran it down instead, so now it goes over the sheave inside the boom cap. Is this correct for the reef line?
3) The same line runs thru one of the shackles for the tack. It should not. Again the lead isn't fair and will have too much friction. It should go directly to a turning block (Type of which depends on where you want the line to terminate.).
Is this good?
4) Image 10 shows that same line going thru the shackle for the vang. It should not. That line needs to leave the boom with an exit block or plate, go to a turning block and then to another block on the deck that will direct it to a terminus.
Is this better? Same as the photo above, but then I added a block like you suggested.
5) I'm not sure the sail is on correctly. The re-enforcement of the cringle at the mast looks like what is done at the leech. Is the sail on backwards?
The sail is on correctly, the sliders are in the mast. It is a very heavy sail, perhaps it has extra reinforcement.
6) What is the timber across the companionway for? Is it temporary?
Yes, it's there temporarily for lowering the engine back into the boat soon (the engine had problems also).
7) For the aft end of the boom I can't follow all the lines. But again the one running thru the pad eye on the bottom of the boom should not and it shouldn't be necessary to loop around the outhaul and boom to hold the sail closer to the boom. Those line will saw thru each other in short order. The outhaul properly run is the answer for that.
If you're referring to the padeye at the underside of the aft end of the boom, that is just a separate line I have running to a cleat to hold the boom steady while working on it.
8) On the port side there is not a deck organizer on the deck as there is on the right side. I would install one for your jib halyard and what ever other lines may be used (Reef lines)?
The jib halyard is self-contained (a CDI FF6 furler). I have the reef line going through the deck organizer on the right side.
9) At the base of the mast the most aft line (Main halyard?) seems ok but the next line up is coming out around that block in an unfair direction. So whatever that line is it will have too much friction and will chafe. The next line (Most forward) can't be led anywhere except athwartship unless it goes to a turning block of some sort. What is that line for. It looks a little like a messenger to me.
The gray line is the main halyard, the white line is just a spare 3/8" line that I use for the mast climber equipment to climb the mast.
10) In image 2 there is a standing block forward of the vang with a line running thru it but I can't tell where the line originates or terminates. That's a nice block but it needs to be put to good use.
The standing block is for the main sheet line, which goes from the blocks on the underside of the boom through the standing block and then to the deck organizer and then to the clutch. This is what is shown in the manual.
I hope this is helpful and not taken as critical. You just need to de-rig and start over.
Is this all correct now? I still am not sure how to rig the outhaul and what to do with the reefing line after it exits the aft of the boom.
Thank you for your help, it is really appreciated.