I want to replace the two sheaves in the masthead on my 1978 DSII. They appear to be held in place by some sort of pins. (Don't look like normal rivets anyway) What sort of tool will work best to get the old ones out and insert the new ones? Barry
Masthead sheaves
- Thread starter Barry1957
- Start date
- Status
- Jan 22, 2008
- 519
drilling out
Although I have owned a DS II, I have not had opportunity to do that type of repair. Having done similar repairs on the mast and boom however, I can suggest using a titanium bit on your drill to take off the bottom of the ?axel?. I have also used a grinder bit on a dremmel type rotary tool to grind off the top of one end to be able to slip it out.
Although I have owned a DS II, I have not had opportunity to do that type of repair. Having done similar repairs on the mast and boom however, I can suggest using a titanium bit on your drill to take off the bottom of the ?axel?. I have also used a grinder bit on a dremmel type rotary tool to grind off the top of one end to be able to slip it out.
Masthead sheave reply
Barry, The pin that you're referring to may be a drift pin. Drift pins can be removed with a drift pin punch set, which is a flat ended cylindrical tool for banging the drift pin out with a small hammer. The drift pin is split length wise so that it fits the hole tightly. If you can bang it out, you'll be able to reuse it for the new sheave. When in doubt, Call Rudy. Joe
Barry, The pin that you're referring to may be a drift pin. Drift pins can be removed with a drift pin punch set, which is a flat ended cylindrical tool for banging the drift pin out with a small hammer. The drift pin is split length wise so that it fits the hole tightly. If you can bang it out, you'll be able to reuse it for the new sheave. When in doubt, Call Rudy. Joe
Barry, If the other side looks like this side of the mast, the only thing you can do is try to grind it out with a Dremel Tool very carefully. Once you get those pins out, you can use bolts for the sheaves. I used a bolt for the sheave on my Z-Spar mast. Grind it out and use a cold chisel to get the cap off. Once the cap is off you should be able to pound the pin out with a hammer and a drift pin punch. If there is any room to get a hack saw blade inside between the sheave and the inside of the extrusion, you may be able to cut the pin, too. Joe
Replacing masthead sheaves
Thanks for all the suggestions. The hacksaw did the trick. Took the blade off and inserted, then put the handle back on to cut. Then used a screwdriver to break up the sheave, afterwhich using the flat end of the screwdriver and a hammer got one part of pin dislogged. Used a "nail punch" through the now open hole and got the other one that had been sawed flat to inside of masthead. Replaced with 1" sheaves from Rudy at D&R with 1" x 1/4" stainless bolts. Working great.
Thanks for all the suggestions. The hacksaw did the trick. Took the blade off and inserted, then put the handle back on to cut. Then used a screwdriver to break up the sheave, afterwhich using the flat end of the screwdriver and a hammer got one part of pin dislogged. Used a "nail punch" through the now open hole and got the other one that had been sawed flat to inside of masthead. Replaced with 1" sheaves from Rudy at D&R with 1" x 1/4" stainless bolts. Working great.
- Status