• Action: To Do List item A0168 - Replace turnbuckles and both whisker and bobstay stay rig wire.
• Completed: 4 November 2016
• Cost: $822.80

The problems with the shortness of the bowsprit whisker stays and use of shackles to compensate for this issue was the reason these wires were to be replaced.  After reading "The Complete Riggers Apprentice", by Brian Toss, and more practical advice/examples found on the internet, we felt this task was doable.  First we did the recommended pin-to-pin measurements which for both the whisker stays was 10' 8", while being a nice to know number, we decided to follow the more practical and common sense approach used by many others describe on the internet - just use the old rig assembly as the example for the new assembly.  As to the issue of size of wire used for each location and is it the correct size, we concluded that what was installed had worked for previous owners for actually quite a long time - common sense says do not fix/change something that is not broke unless you have a really good rationale. Also the current existing wire size on Indra was actually metric not imperial - we opted for imperial based on supply source.  Lastly from a more technical view point, the original design of this boat by the designer, revealed he determined that 1/4 inch wire for all locations was sufficient.  Current wire size was beefed up by someone in the past - the bobstay was 3/8 inch; the backstay, forestay, cap shrouds, forward lower shrouds, and aft lower shrouds were 5/16 inch; while the whisker stays, boomkin stays, inner forestay, intermediate shrouds, and aft adjustable stays remained 1/4 inch.  As this beefed up rig size had worked in the past, we opted to follow the same sizing methodology.

The bowsprit whisker stay rigging was of 1/4 inch wire size with 1/2 inch rig pins on each end.  Estimate of the 1/4 inch wire length needed was very close to 9' 3" with everything laid out, pulled taught, and measured; but would order a minimum 10 foot length for both the port and starboard whisker stays to be safe.

The bowsprit bobstay rigging was of 3/8 inch wire size with 5/8 inch rig pins on each end.  Estimate of the 3/8 inch wire length needed was very close to 73 inches.

The choice of end fittings for the wire rigging was partially decided by the lack of local options - there were no rigging shops so machined swage fittings were not an option.  After reviewing the literature for different mechanical rig fittings, which is probably the best option for do-it-yourself rigging, selected Sta-Lok Swageless Terminals for all wire terminations needed on Indra.  For turnbuckles, selected to use all open body forged bronze stainless steel coated Hayn Marine turnbuckles.  All items (including boomkin rig and spare cones) were ordered from an outfit called Rigging Only over the internet.  They shipped the order to our ocean freight consolidator and forwarder in California, Manila Forwarder, and after a boat ride, we received it on 17 October 2016; about two months from initial order.

Upon inspection we found that they had incorrectly provided one left hand toggle in lieu of a right hand toggle, so we were now short one complete turnbuckle assembly.  This part issue would take another couple of months to end up with the correct pieces.

Also two of the open body turnbuckles had issues, could not turn the toggle in by hand, threads were binding up.  Even after lubricating the threads, and working the threaded stud in and out multiple times, it did not improve.  Discovered that whoever made these turnbuckles did not cut the threads all the way through the turnbuckle causing the thread binding issue.  Simple enough, used a tap, and recut the threads; fixed this issue.

At the boat, the port whisker stay was removed first to be used as the example.  A Sta-Loc toggle fork was attached to the roll of 1/4 inch 1x19 wire per the manufacture instructions. The instructions recommend using a screwdriver to unravel the outer lay of the wire - this does not work very well.  Advice and videos on the internet show using pliers to grasp the whole wire and one quick twist they are unraveled properly - this worked effectively.  We assembled it the rest of the way with no issues - this was actually easy to do.  The instructions state, "...tighten with spanners.  TIP: Undue force is not required to terminate wire."  This final tightness/torque vagueness was discussed on the internet with different recommendations, from giving it a 1/4 turn from fully seated to using a breaker bar on a wrench to muscle it super tight.  The manufacture should really advise use of a proper torque value for clarity.  We did not fully tighten down this fitting as we reopened it to verify the crimp placed on the wire which looked ok, and then reassembled it still not fully tight.

We secured the end of the original whisker stay, the new Sta-Loc toggle attached to the roll of wire, and a tape measure to a long screw driver held in place and stretch them out.  We decided to cut at 9' 2" length and used a Dremmel rotary tool with metal cutting wheel, which worked very well.

A Sta-Loc eye terminal was attached to the end of the wire, again not fully tightened, and pinned to the turnbuckle.  Next the rig assembly was test installed on the boat to check for fit, which also appeared acceptable.

The rig assembly was removed for the final assembly.  As a result of internet research on the issue of water intrusion into lower rig fittings and subsequent corrosion, just like the machine swage fittings on Indra exhibited, decided to apply sealant, 3M Marine Adhesive/Sealant Fast Cure 4200, into the fitting prior to final tightening with red thread locker on the threads.  Also worked in a little Forespar LanoCote anti-corrosive liquid into the end of the wire prior to application of adhesive and final torque of the Sta-Loc terminal.  Only time will tell if this is a effective strategy.  The completed whisker stay assembly was then remounted on the boat.  We decided that on placement of turnbuckles, the left hand threaded stud side would always be attached to the boat fixture, so a consistent method of tightening or loosening would apply.

The starboard whisker stay was assembled next, followed by the bobstay, and used the same procedure as described above.

The cost for each assembly is listed below: