replacing halyards....
First, it's not nylon.... it's polyester or a blend. nylon will stretch, fray, not run well.. Take five minutes and read the west marine advisor as Stu recommends.Second, you haven't mentioned why you want to replace the wire/rope halyard with all rope. Is it to save money? You can order a new, pre-spliced, wire/rope halyard from defender.com for well under a hundred dollars.Finally, the most important thing you need to know about the masthead sheave is it's width. Since you don't mention what kind of boat you have, check the specs on your boat and see what size the sheaves are, then make your decision to replace with dacron/polyester or wire/rope. I will guess that you're using a 1/8" wire/3/8 inch rope. One advantage of wire halyards, besides very low stretch, is that they allow a very narrow sheave. On my Cat 27 the sheaves are just over 1/4 inch wide, which restrict the size rope that will run freely. You can use rope in the wire sheave, but it must be small enough to run well. Last week we talked about tapered and stripped halyards. That is one solution for the small width sheave problem. Or you can change the sheave. Check the archives for those discussions.