Replacing outhaul in boom

[Trevor]

Hello trusty sailors...I have a loose-footed mainsail that I love, but am not able to take advantage of the additional outhaul control. It seems I can barely move the outhaul at all with that tiny line and high pressure. I am considering replacing the outhaul inside the boom with extra mechanical advantage (say 6:1 instead of the reported 3:1). Has anyone ever done this? I don't even know how to take my boom apart! Hoping someone can help,TrevorSV Dunoon1986 C36TR #640

 

[Chuck]

outhaul

First you need to take the screws out of the end caps. That may be a trick in it self from what I under stand. There are also a bolt on each end they are only about 4" long. You will then have access to the inside of the boom.I have not started this project on mine yet, so I have no real experience, this is what I have learned doing my own research. There is supposed to be a 3:1 purchase in the boom. You can change it to a 6:1 purchase. Good Luck and I hope this helped.

 

[Chuck]

Follow up With Diagram

Click on the related link for a diagram of the boom interior. I found this in my archives. Thanks to whoever it was, that posted this.http://www.tcsn.net/bosun/c30/outhaul.htm

 

[Trevor]

Thanks Chuck

I managed to remove the boom over the weekend and have a dry basement to work on it. As you suggested might be a problem, my first challenge is going to be getting those screws that hold the end caps on! I'll let you know how things progress; I appreciate your posts!Trevor

 

[Tom Soko]

Another idea

Trevor,I noticed another post on this subject in a different web site, and someone mentioned using NAPA's PB Blaster for dissolving the corrosion between the SS screws and the aluminum. I took my boom apart a few years ago and replaced the ss self tappers. I drilled and tapped 1/4x20 threads for a short hex head bolt. MUCH easier to take apart now. I would also suggest taking off the "outhaul car extrusion" on Chuck's drawing. Too easy for it to bind under tension. Have you sailmaker sew on an aluminum lug at the clew of the mailsail, and attach the outhaul directly to the clew cringle. Outhaul sheave can also be replaced with a ball-bearing sheave, and the internal blocks can be changed to give you a 6-1 purchase. Good Luck.Tom SokoJulandra C36#659

 

[Hayden Watson]

Add a cascade

You can change your existing 3:1 to a 6:1 or 9:1 by adding a block or two at the end of the boom on the outside. If you put a single block on the clew of the sail and dead end the wire pendent on the end of the boom you have a 2:1 cascade the multiplies the 3:1 to 6:1. If you use a single with becket on the clew and a single at the end of the boom you have 3:1 times 3:1 for 9:1. I did this to my C30last year. There is enough wire in the boom for either option. Use the wire sheeve blocks that they sell at West Marine. They are cheep and strong. If you go this way you should use ball bearing blocks inside to make that end as free running as possible. you will also find that this system is much smoother than an internal 6:1 tackle.Hayden WatsonPapillon1988 C30 tr/bsSpokane, WA

 

[Trevor]

I'm almost inside!

Well, I have 7 of th 8 screws off the endcaps and the forward one is off the boom. I managed to strip the last screw on the aft cap. I followed this up by breaking a drill bit in the hole in an attempt to drill the screw out. I used PB Blaster which helped get some of the harder screws out but this last one has really been a pain. I plan on at least replacing the wire that attaches to the clew since the plastic coating is all cracked and adding friction. I like the idea of going to 6:1 but may look into the cascade that Hayden mentioned.Thanks for the support; I'll let you know how I make out.Trevor