- Action: To Do List item B0204 – Obtain replacement and spare outhaul car 3/8 inch x 1.25 inch long clevis pin with 1 inch cotter pin.
- Action: To Do List item B0205 – Obtain replacement 1/8 inch wire to 3/8 inch double braid outhaul halyard.
- Completed: 16 November 2018
- Cost: $170.10
The following items were purchased for this task.
| P/N | Item | Q | Each | Total |
| H-440-1240 | Main Outhaul 1/8" wire x 3/8" rope - U.S. Rigging Wire-To-Rope Halyard Kit | 1 | $110.39 | $110.39 |
| 608718 | S & F Tool Swage-It Tool | 1 | $52.43 | $52.43 |
| CP38114 | Clevis Pin 3/8" DIA. X 1 1/4" Grip | 2 | $3.64 | $7.28 |
| TOTAL | $170.10 |
Upon receipt of the new wire-to-rope halyard noticed the length of the 1/8-inch wire and 3/8-inch double braid rope was 40-feet each. This would most likely need to be trimmed down when installed.
Removal of the original outhaul wire-to-rope halyard was in a very confined area (yellow arrow) and if botched, was not sure how a replacement wire could ever be routed in the very restrictive area of the Ronstan RF456 exit block. We first removed the two stainless steel screws (red arrows) attaching the stainless steel eyestrap using an impact driver and hammer to free the wire thimble. We cut the wire thimble off the end off the wire and attached a messenger line made of Samson Lash-It Dyneema fiber 2.2mm line to the wire and also wrapped it securely to the wire with black electrical tape. The outhaul rope was then pulled out of the boom from the opposite end - actually easily done. The new replacement outhaul wire-to-rope halyard was attached to the messenger line and pulled back through. Had a small delay as it had to be wiggled back and forth multiple times to pass through the Ronstan RF456 exit block.
Closer inspection of the original outhaul wire-to-rope halyard revealed many broken wire strands and areas of rust and corrosion.
The new 1/8-inch wire was trimmed to a length of about 8-feet - 32-feet was cut off as excess and retained. It was then formed around a stainless steel thimble and secured with a compression sleeve. The thimble was routed through the stainless steel eyestrap and the eyestrap was secured with two stainless steel screws that were coated with Lanocote.
The excess length of 3/8-inch double braid rope is about 30-feet if we retain the original end point on the starboard side of the boom. The rope was not cut yet as we consider if we might want to run it aft to the cockpit area and it was temporarily stowed on the boom.
Installed the new outhaul car 3/8-inch x 1.25-inch long clevis pin with 1-inch cotter pin.
