Cotter pins can tear sails, & flesh.
Which is why this solution, which has served me well for about 25,000 miles, is the answer. Despite being from Brian Toss, one of the world's great riggers, I have never seen it on any boat but mine. I've had boat yard riggers slap themselves on the head when they see it and say, "Why didn't I think of that?"
Go to a welding supply outfit and buy a bundle of 316 welding rod. It will cost you 20-30 bucks for a lifetime supply. Bend it into a "[" shape, insert, and bend the ends in. It can also be done with the NavTec turnbuckles that have the threaded part in the middle.
I've never had a hint of trouble or snags with this arrangement.
While we are at it, this is the proper way to do cotter pins, straight (in my case) from the mouth of the great Rod Stephens:
Cut the cotter pins short and round and smooth the ends with a fine file or sandpaper. You'll have to start splitting them with a knife but a typical rigging knife does this easily. Bend just enough, Rod used to have a little wooden wedge he carried around to be sure the angle was exactly right. Mine may be bent a hair too much.
The idea is to not bend the pin so much that the character of the metal is changed in the bend. That will promote crevice corrosion that may lead to it breaking and falling out.
I've never had a snag or bloody toe with this arrangement. No tape on my boat anywhere.
BTW I think it was at this event, committee meeting for the
Corwith Cramer design, that Rod (second from right) talked about this. I'm third from left. Oh yes, that's Irving Johnson in the rear middle with the fellow on the right of him looking at him. Drayton Cochran, former owner of the
Westward, where the photo was taken, is just in front of him.
