Mast Hardware / Sheave boxes

All four sheave boxes are now installed at the mast:

Pole Lift box: the opening in the mast was slightly reworked and cleaned off, then a G10 plate was glued to the bottom of the opening to prevent the open box from cutting into the end grain of the wood. We also replace the axle of the sheave box with a thru bolt all the way thru the mast, the thru bolt is further strengthened by G10 bushings which are glued into the mast.

Jib Halyard Sheave Box: This is one of the boxes that was completely new designed and manufactured. The box is slightly bigger in height and includes a rounded bottom area that spreads the load on the end grain of the mast opening. This box was designed as a one-piece design including the “wings” that spread around the mast all the way to the thru bolt on which the sheave is mounted. We also added G10 bushings to the thru bolt – glued to the mast in order to further spread the load.
The area which received a scarfed in piece during the repair in Helsinki was faired to the rest of the mast and received multiple coats of varnish to nicely blend in with the rest of the mast.

Spinnaker Halyard sheave box: This box was modified by adding a half round piece of bronze to the bottom of it to spread the load on the end grain of the mast opening. We further replaced the small axle in the box with a thru bolt (3/8″ bronze) which is sitting in G10 bushings (9/16″ OD) glued to the mast.

Main halyard sheave box: This box was completely re-designed and newly manufactured as the previous box had already started pulling thru the mast and had cracked from stress in one corner. Again – this box is manufactured from one piece of bronze plate including the wings that wrap around the mast and hold the thru axle in place. The axle is set in G10 bushings glued to the mast. As per discussion with Jacob Vargish we placed the new box around 1″ higher than the previous one to improve the angle of the halyard to the sail headboard. As with all the other boxes any damages to the mast resulting from stress or the previous sheave boxes were repaired with dutchman.

Cockpit bench: The cockpit bench for the helmsman was built from light cedar and fits nicely into the cockpit. There are no fasteners to hold it in place, it simply drops into cleats that are attached to the frames and hold the bench in place but also allow a very fast removal of the bench if necessary. Jamie estimated the weight of the bench at 11 lbs, the cleats may add another 3 lbs.

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