Was I lucky or what? Forestay failure!

Jan 7, 2011
5,972
Oday 322 East Chicago, IN
My O’Day 322 is about 38 years old. Always sailed on the Great Lakes, stored indoors for many years of her life (but not in the last 12 years). I have owned her for 12 years, and we sail in challenging weather all season long. In the past few weeks, I have been out in 8 foot seas and 20 knots of wind. I was in 25 knots True wind the other day while trying to do a single-hand challenge sail (100 nm in 24 hours). But I take Tally Ho out in all sorts of crazy weather.

Today, I went out for a Labor Day sail. East winds about 10-12 knots. Seas about 2-3 feet. Not an uncomfortable sail at all. I was tinkering with my AP and tightening the belt tension a little as it was slipping when out in 18 knots yesterday. Got it dialed in just right and was letting AP handle the helm duties. A lovely sail looking at the Chicago skyline to the north and at about 10 miles out, I was about ready to tack for home.
IMG_6792.jpeg
But before I tack, something POPS at the front of the boat, the furler starts slamming around inside of the bow pulpit and the backstay goes slack! In my mind, I knew it was something with the forestay, but I wasn’t sure what happened. I made my forward enough to see that the furler drum is banging around, the jib is a mess and I need to do something FAST. Luckily, the winds are pretty light at 10 knots.

I get back to the cockpit and drop the main halyard. The sail doesn’t fall all the way down into the Mack Pack because we are not pointed into the wind, but it did drop some. Next, I turn my attention to the jib. With the furler out of commission, what do I do with the jib? My first thought is to try and pull it onboard and wrap a line around it to try and keep it around the stay. But that didn’t really work.

Dropping the jib is the logical thing to do, but Tally Ho has an older CDI furler, which uses an internal wire halyard, and a shuttle car that gets pinned to the foil. Very difficult to raise or lower the sail…but since I only do it 2x per year, I put up with it…. But now, I need to drop the jib! So down in the cabin to grab some tools. It takes some work, but I finally get the pin out, and the sail comes down about 4 feet, but then gets stuck. Loooking up, I see the foil is a bit kinked and curled since the stay is slack. I can’t get the sail down at this point.

I turn my attention to the securing the furler drum, since it is still banging around inside of the bow pulpit, and banging down on the deck. Every time the wind puffs, the furler lifts, bangs around and falls hard back on the deck. I grab a spare dock line, head forward again and secure the line around the anchor roller, through an eye on the furler drum and back down to the anchor roller and then back to a bow cleat. Pulling hard, I put as much tension in the stay and furler as I could….not tight, but it kept the drum from banging around so much and added at least a little support to keep the mast from falling aft.

Then to my surprise, I looked at the foil and the jib was 1/2 way down! I pulled and it came all the way down to the deck!

Now we are getting somewhere… but we are still heading away from the marina. So, with the jib down on the deck, and the furler somewhat secured and providing a little support for the mast, I decide it is time to start the motor and start a slow ride back to the marina. The seas are 3-4 feet now, and I decide to bring the main halyard forward to the anchor roller and then tightened it on the winch.

The mast looked surprisingly stable (my biggest fear was it would fall aft and that would be that). I motored in the bouncy seas, and kept a close eye on the shrouds, back stay and halyard securing the mast from the bow.

I got Tally Ho back to the marina and got a close look at the failure point…very surprising to me!


I am not sure what this strap is called…

IMG_5255.jpeg

but it continues up and ties into the stay…

IMG_6811.jpeg

but it broke very cleanly…
IMG_6813.jpeg IMG_6819.jpeg

Ironically, I had gotten an estimate from our local boat yard to unstep the mast and replace the standing rigging this winter. I hadn’t committed yet, but after this warning, I am more inclined to make the investment.

This whole thing could have been a lot worse…if it happened in 8 foot seas, or 25 knots of wind, or if the mast came down in a hurry!

Tomorrow I hope to get the stem fitting strap (both pieces) off the boat and to find a machine shop to fab a new one. With that, I could secure the mast for the winter. Or I can take it to the boat yard to have the rigging replaced…either way, the strap needs to be replaced.

But I think my sailing season with Tally Ho is over for this year. :( But hey, I sailed 54 days this summer, so I can’t complain too much.

Greg
 

Blitz

.
Jul 10, 2007
724
Seidelmann 34 Atlantic Highlands, NJ
Wow - play the lottery bc you are lucky

That thingy was acting as your chain plate. Broke is a way, as if it was cut. Probably over stressed for years.
 
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Jan 7, 2011
5,972
Oday 322 East Chicago, IN
Wow - play the lottery bc you are lucky

That thingy was acting as your chain plate. Broke is a way, as if it was cut. Probably over stressed for years.
Yes, it is a very clean break. Hope to know more once I get the pieces off the boat for inspection.

Greg
 

BarryL

.
May 21, 2004
1,124
Jeanneau Sun Odyssey 409 Mt. Sinai, NY
Hey,

I'm not trying to be an ass. Standing rigging does not last forever. In salt water (where I sail) I replace my rigging after 15 years. If I were in fresh water I would go longer, maybe 20 years. Your rigging is almost 40 years old. You are way overdue for replacement. Normally the chainplates aren't replaced during a re-rig. However a thorough inspection needs to be done. I bet that if you had carefully inspected your rigging you would have seen signs of failure - stress cracks, stains, elongated holes, before the chainplate failed.

Good for you for sailing in challenging conditions and for being able to save your rig and get home. Very impressive.

Barry
 

jssailem

SBO Weather and Forecasting Forum Jim & John
Oct 22, 2014
24,695
CAL 35 Cruiser #21 moored EVERETT WA
Wow Greg. Very Fortunate. Really reminds us that the rig should be inspected regularly.
You discovered the problem. Made a plan. Executed the plan and brought your boat safely home to port. Very good Seamanship.:biggrin:
 
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Jan 7, 2011
5,972
Oday 322 East Chicago, IN
Hey,

I'm not trying to be an ass. Standing rigging does not last forever. In salt water (where I sail) I replace my rigging after 15 years. If I were in fresh water I would go longer, maybe 20 years. Your rigging is almost 40 years old. You are way overdue for replacement. Normally the chainplates aren't replaced during a re-rig. However a thorough inspection needs to be done. I bet that if you had carefully inspected your rigging you would have seen signs of failure - stress cracks, stains, elongated holes, before the chainplate failed.

Good for you for sailing in challenging conditions and for being able to save your rig and get home. Very impressive.

Barry
You are absolutely right Barry. Well past due.

i stripped the sails, boom, etc off the boat today so i can move it to the yard.

But lesson learned….i waited too long, And I was fortunate it didn’t go much worse.

Cheers,

Greg
 
Jan 7, 2011
5,972
Oday 322 East Chicago, IN
Wow Greg. Very Fortunate. Really reminds us that the rig should be inspected regularly.
You discovered the problem. Made a plan. Executed the plan and brought your boat safely home to port. Very good Seamanship.:biggrin:
It is ironic that I called the yard this summer to get info on replacing the standing rigging. But I will admit I hadn’t committed as of the day the strap broke.

This makes the decision a lot easier.

here is where it broke… note that the strap is bent (intentionally) where it broke….

IMG_5261.jpeg

IMG_5259.jpeg
 
Jan 7, 2011
5,972
Oday 322 East Chicago, IN
Metal fatigue induced by bending?
It certainly looks like it.

I was able to get the strap unbolted and the top part removed from the toggle.

Called several machine shops today to see who could fabricate one. Have a promising lead that I will go visit tomorrow and take the part so they can see it and take measurements.

Still waiting for our local boat yard (Crowleys) to see what they think.

Removed the main sail, boom, vang, and all lines e crept the main halyard that is helping hold the mast forward…all in anticipation of taking to Crowleys to pull the mast and replace all of the rigging.


Anyone have a recommendation on a solid furler to replace my old CDI? I actually like the drum size of the CDI, but not too keen on the internal halyard…..but have never had to worry about halyard wrap!

IMG_5265.jpeg IMG_5267.jpeg IMG_5262.jpeg IMG_5263.jpeg

Greg
 

dLj

.
Mar 23, 2017
5,154
Belliure 41 Back in the Chesapeake
Metal fatigue induced by bending?
It could be fatigue but not from bending if manufactured correctly. Without looking at the fracture surface with a microscope the cause can't be determined. Fatigue is typically the propagation zone. It is not commonly the origin. The only thing the propagation zone does is tell you the environmental conditions the part is subjected to during its life span. The reason the fatigue started is found by analyzing the origin zone.

There are three distinct phases in all fractures - origin zone, propagation zone and final fracture zone. Very few boat yards have the expertise or equipment to actually analyze fractures.

The most important zone to analyze is the origin zone. It can't be analyzed by eye. It usually can't even be seen by eye. I have seen literally hundreds of these kinds of failures be in correctly diagnosed.

dj
 
Last edited:
Feb 26, 2004
23,448
Catalina 34 224 Maple Bay, BC, Canada
Anyone have a recommendation on a solid furler to replace my old CDI? I actually like the drum size of the CDI, but not too keen on the internal halyard…..but have never had to worry about halyard wrap!
ProFurl, no halyard wrap. Harken other excellent choice.
 
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Sep 17, 2022
227
Catalina 22 Oolagah
Tally Ho, what a story. Your cool head coupled with, both seamanship and luck turned what might have been an expensive (not to mention, dangerous) disaster into a Lessons Learned tale of caution. By my own admission I’m very conservative. That’s why my 38 year old boat had new rigging installed before her launch several years ago. I also have waiting to be installed new lifelines even thought I have no indication my current lifelines are corroded. With 38 years of service, I believe though hidden, the corrosion is there and needs to be addressed before a failure occurs.

I hope a lot of folks read your cautionary tale. It probably should be a “Sticky”. Many of us purchase used boats. (It’s just the way it is. Oh Baby!) Unless you have providence of your new to you sailboat’s rigging‘s age, one of the first items on the list should be upgrading the standing rigging.

Again, Tally Ho. My hat’s off to you for your cool head, seamanship and sharing with us.

George
 
Jan 7, 2011
5,972
Oday 322 East Chicago, IN
Tally Ho, what a story. Your cool head coupled with, both seamanship and luck turned what might have been an expensive (not to mention, dangerous) disaster into a Lessons Learned tale of caution. By my own admission I’m very conservative. That’s why my 38 year old boat had new rigging installed before her launch several years ago. I also have waiting to be installed new lifelines even thought I have no indication my current lifelines are corroded. With 38 years of service, I believe though hidden, the corrosion is there and needs to be addressed before a failure occurs.

I hope a lot of folks read your cautionary tale. It probably should be a “Sticky”. Many of us purchase used boats. (It’s just the way it is. Oh Baby!) Unless you have providence of your new to you sailboat’s rigging‘s age, one of the first items on the list should be upgrading the standing rigging.

Again, Tally Ho. My hat’s off to you for your cool head, seamanship and sharing with us.

George
Thanks George.

i should be more like you (conservative). Too often I am a run and gun type of guy.

But if anyone learns the importance of having the rigging checked from my story, it is worth telling the story.


Cheers,

Greg
 
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JRacer

.
Aug 9, 2011
1,406
Beneteau 310 Cheney KS (Wichita)
I have a Selden Model 200 on the First 310 and am happy with it. Yes, you should be stocking up on lottery tickets. Good job getting yourself through that potential disaster.