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Expert advice from PBO's Mike Coates & marinechandlery.com |  View this email in your browser

* TOP TIPS TUESDAY *

106. PREPARING SPARS AND RIGGING - A STEP BY STEP GUIDE BY PBO COLUMNIST MIKE COATES
UV Damage and Corrosion - Navigation Lights

The next stage in our pre-season  preparations is inspection of the spars and the rigging and assuming your mast is down (easier than dangling from a bosun’s chair, more about that later) we start with the masthead light. Check it’s secure and the lens isn’t suffering from UV damage, check cables for chafe where they exit the light and enter the mast. Remove the lens, then bulb(s) and make sure all the contacts are clean by using the excellent specialist fast drying contact cleaner, if they are the filament type bulb our recommendation is to replace regardless (keep old as a spare) or consider going for replacement LED bulbs, a lot less current drain and almost bullet proof in a heavy beat to windward!  However, remember you shouldn’t put a white LED behind a coloured lens, only use a coloured LED bulb. After replacing the bulbs, spray electrical connections with Boeshield and then clean the lens both inside and out. Before replacing the now clean lens, you must of course check the lights are working (our Top Tip is to use a small 9 volt alarm battery and connect to the wires where they exit  at the bottom  of the mast, it’s much easier than lugging round a big heavy 110 amp hour beast) once satisfied,  reassemble.

Worn Mast Head Sheave

Check the condition and security of the mast head VHF aerial or combined VHF wind indicator (if the Windex is becoming brittle through UV damage consider replacing) Examine carefully any other antennas like the AIS or Active band transmitter/receiver and of course don’t forget the condition of any cables. Assuming mast head wind speed and direction is stored below deck whilst the mast is down, check manufacturer's handbook for information on lubrication and maintenance, clean contacts as above and once again spray with Boeshield after refitting. As for me I prefer to leave the transducer off when the mast is being refitted as the ‘small print’ of a boatyard’s terms and conditions often does not cover you for accidental damage, yes its a mast climb however replacement transducers can set you back £400-00! Satisfied with your mast head gear? Now turn your attention to the mast head and check all masthead sheaves for damage and wear. On some masts especially older Selden (Kemp) it’s impossible to replace the sheave without taking the masthead fitting out of the spar. Clean and then lubricate with a ‘dry’ lubricant don’t use a grease or oil as it attracts grit and can damage sheaves made from  Tufnol (recognised by it’s brown colour/fabric weave) Next check the condition  of the forestay and backstay attachments, draw the clevis pins out, examine them for wear and at the same time check that the ‘hole’ that they pass through has not elongated. If ok, replace and secure with new split pins.

Bird Caging

If you have been unfortunate enough to have suffered a halyard wrap(s) last season, pay particular attention to where the wire strands exit the swaged terminal/talurit splice, flex the wire gently for any sign of broken strands, even  if it’s only one broken strand replace. If the forestay shows signs of birdcaging (wire opening up) you should also replace the forestay without question. Your spinnaker/asymmetric halyard block can take a hammering, out of sight out of mind, so check condition of the side plates, swivel and the shackle. Working your way down the mast, if an older rig and stainless tangs are used for the attaching of standing rigging, examine carefully behind the fitting for signs of corrosion. Consider drilling out the old rivets and replacing with new monel ones after you have used a barrier between the two disimilar metals. If a fractional or similar rig, remove the combined genoa and spinnaker halyard  box, check for stress cracks, worn sheaves and then clean and lubricate as above. Then check the security of the spreader brackets, paying particular attention to rivets and any signs of corrosion underneath a stainless bracket. Turning to the spreader tips, if the rigging is still attached to the spreaders check for a broken strand(s) possibly hidden in the spreader end clamp. Slacken the clamp, move the tip up or down and flex the wire gently. Consider fitting a pair of leather spreader boots once you have satisfied yourself that everything is ok. Steaming and deck flood lights are often neglected, check and service as per your mast head lights.

Broken Nav Light Connection

Check the gooseneck and base of mast kicker bracket for wear, replace if badly worn, replace worn nylon spacer washers. Check for any cracks around halyard exit slots, this is especially important on fractional rigs set up with high amounts of pre-bend, consult your rigger if any are found. Keel stepped spars should have their deck coats/seals checked as it’s impossible to replace them without lifting the mast out again. At this stage don’t forget to run  your eye over the rest of the rigging, examine all rigging screws for damage, if the threaded lower stud is bent replace and pay particular attention to any rigging screw that is not toggled as they do not articulate and are liable to more stress.

Bent Lower Stud
Wash out and lubricate (as per manufacturer’s instructions) halyard swivels and drum bearings on headsail reefing gear – Furlex has a specialist grease. Pay particular attention to the joints in the headsail foil, if slight movement there is a danger of mis-alignement. Consequences; the sail jamming whilst hoisting and you may run the risk of tearing the luff tape. You may also end up with some rather nasty stains on the sail opposite the suspect joints caused by fretting of the alloy. If you have movement it may be a loose rivet or fastening that’s missing or a worn jointing piece. Consult the manufacturer’s manual for details on how to remove and replace. Foils may be cleaned by washing with soap and water. A scrap of luff tape may be run up foil to scrub inside grooves. If lubrication is required, spray a thin coat of McLube SailKote on sail luff tapes away from boat deck. Check the end stop at the top of the foil is secure and that the bearing just inside the top of the foil is still round, if its oval replace!
Sail Staining From Furling System
If you haven’t already removed and washed your halyards do so. Do not wash at a high temperature or use a biological washing powder as it can damage some polyester ropes, preferably leave to soak in water for a couple of days prior to washing. Don’t tumble dry as the heat will damage most synthetic ropes, instead hang out to dry then leave in the airing cupboard for a few days. If using a washing machine place any shackles inside a pair of socks to prevent damage to the drum on the machine and keep the other half happy! Check all eye splices, worn or damaged halyards should be replaced. Wire halyards that are found to have spikes are fatigued and should be replaced as they are on the point of failure, consider replacing with Dyneema, Spectra or similar ultra low stretch materials as it is cost effective and usually has a longer life span.
Fatigued Wire Halyard

When re-stepping your mast replace all split pins that secure clevis pins or lock turnbuckles, mouse shackles with Monel seizing wire, lightly grease all turnbuckle threads with Lanocote or Loctite 8065 prior to re-assembly. Consider fitting turnbuckle covers adding shroud or guard rail rollers or at the very least tape over turnbuckles with self amalgamating tape after setting up your rig which all help to reduce chafe on sails and prevent damage to crews clothing and boots which can easily be damaged by sharp split pins etc.

Mast still up? Read and inwardly digest Spinlocks excellent article on ‘Going Aloft’. Spar and rigging inspection with the mast still up, will take a lot longer as it has to be carried out from a bosuns chair but it shouldn’t be neglected, if for whatever reason you have not removed the rig this year, inspect whilst swinging from halyard(s) and if necessary, budget for its removal next year. If I am climbing and I still do so on a regular basis, even at my advanced age, their Mast Pro harness isn’t the most comfortable but without a doubt the one that I feel most secure in! Incidentally, if I ever have to go aloft alone, then I always use the Topclimber mast climbing kit. All the above still applies however it will take a lot longer and obviously it’s more weather dependant!

Worn Gooseneck

Check the inboard end of the boom casting for wear, check rivets are sound and if any jammers/pulleys are part of the assembly, that any sheaves are free running and not chipped and when the cam lever is rotated they will hold the load from reef and outhaul lines! Check the kicking strap slide (if alloy) for wear from the stainless shackle/attachment point on the strut/strap assembly, make sure any fastenings are man enough for the job and that the slide is not creeping towards the mast. Examine the boom in this area for any stress cracks and corrosion from stainless fastenings if used to secure. Next check the reefing lines take off attachment eyes are secure and then pull through the lines for signs of chafe. Make sure that when you come to fit the main back on the boom, you reeve the reef line under the boom first to ease the load on the fitting! If the main sheet pulley blocks are secured mid boom as against attached to the end casting examine as per kicking strap slide. Next the outboard boom casting, check the condition of the pulleys then check (if end boom sheeting) that the shackle securing the mainsheet block still has plenty of alloy left on the attachment casting. If you still have a wire outhaul check for spiking in the lay of the wire and if any are found replace. Reef lines, especially in single line systems, can be a source of friction. If fluffed up, consider changing as the difference when putting a reef in can be chalk and cheese.

Finally if you haven’t already done so, now is the time to give the mast and boom a wipe over with Hempel’s Alu-protect, it’s a silicone free oil for cleaning and protecting alloy spars!

LOOK OUT FOR NEXT WEEKS TOP TIPS - BELOW DECK
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