New Mainsheet track

[tomlax12]

Hello all, I have an 1976 Oday 25 and am in the process of updating the old running rigging. With that being said, I am ready to purchase a new mainsheet traveler and track, and have decided to go with the Lewemar 00 track. It takes a hex bolt that slides inside a slot in the new track so as to be able to use the old holes. My question is that with the size of the new bolt being so much smaller in diameter than the old bolts, it is safe to use, and will it hold? Thanks, Tom

 

[Brian S]

I say you just fill the existing holes with thickened epoxy, and then re-drill for the correct fastener size. Given that O'day decks are balsa cored, it's not a bad idea to do this anyway...

 

[Ward H]

Curious what size bolts your new track is using. The bolts on my original 1980 25 are 1/4". Hard to imagine smaller bolts could be used. I can't tell if there is wood sandwiched or backing under the track.
Brian's idea is a good one in any case. West System 610 Thickened epoxy in a tube is good for this.

 

[tomlax12]

Well the way the Lewmar track works is the head of the bolt slides into a slot on the underside of the track. That way you just slide them into the old holes, not requiring new holes. But the track itself is not as wide as the old track, so my assumption is to just use washers to make sure they don't pull through the deck. The other issue of installing the track, and getting around underneath the cockpit is another issue.

 

[Ward H]

On ours, the aft starboard qtr berth has a "trap" door on the cockpit side. Once you drop that down, the panel above it can be removed by taking out 4 screws. Gives you more access to the underside of the track. A long extension with deep socket should do the trick. I'm always amazed how they use regular size washers under the nuts. I always install fender washers. For 1/4" machine screws I have found 1" and 1 1/4" fender washers. I always use the largest that will fit. I am also amazed they always use hex nuts without lock washers. I add lock washers or if the bolts are short, I use nylock nuts.
Be sure to use a good bedding material on the bolts. Even if it is all fiberglass there, your DC panel is under that location.

 

[RichBone]

1/4" is more than adequate. Going smaller to 3/16" would still be strong enough especially since there are other bolts there to spread out the load.