Great Post Donalex
The relationship between sheave diameter and rope diameter is one of the reasons that smaller line runs more easily on the same sheave. Lewmar stamps this information on the sheave of their blocks, i.e. "Maximum Line Dia. 3/8" and "Optimum Line Dia. 5/16"For boat shows I have a setup that has the Max line dia on one set of blocks and Optimum dia on another to show the difference. People tend to choose hardware backwards. They choose the smallest, least expensive hardware that will pass the line and end up with tackles that are much less efficient than they could be.I think if you were to repeat the experiment and compare lines of equal strength over the same sheaves you might find that the smaller diameter high modulus line does not incur a friction penalty.3/8" Poly double braid is rated about 4400 pounds3/16" Spectra is rated at about 5000 poundsI wonder what the results would be if you compared 3/8" double braid to 3/16" 12 strand over the same size sheave? Of course no one wants to trim a 3/16" diamter mainsheet so the experiment has little value for hand tackles. The shape of the sheave also effects the efficiency. Wire, conventional, and hi-tech line are happiest running on different groove shapes. Kevlar cored line is very fussy that way (thank goodness Kevlar is not the core of choice any longer).If you use 10% internal friction loss over each sheave you can see that adding parts to a tackle has diminishing returns:1:1 > .9:12:1 > 1.8:13:1 > 2.7:14:1 > 3.6:15:1 > 4.5:16:1 > 5.4:17:1 > 6.3:18:1 > 7.3:1In the real world 15-20% loss from using the wrong size line is a better number and if you have a 5% loss in the sheave bearing, tackles greater than 4:1 look pretty bad:1:1 > .75:12:1 > 1.5:13:1 > 2.25:14:1 > 3.0:15:1 > 3.75:16:1 > 4.5:1Changing a 4:1 mainsheet tackle from the largest line the block will handle and changing from plain bearings to ball bearings has the effect of changing the tackle from 4:1 to 5:1What this means when selecting hardware is that for easy adjustment under load like a mainsheet system, you need to pay close attention to line size, bearings and sheave diameter. For tackles that are set and not adjusted under load you can size the hardware to the load and not be so fussy about line size, bearings and sheave diameters.