Cap Shrouds

• Action: To Do List item A0173 – Replace all turnbuckles and rigging wire.
• Completed: 20 March 2018
• Cost: $761.66

Ordered and received the following items for the cap shrouds:

We removed the port side cap shroud first by cutting the wire right above the turnbuckle stud terminal. Then went up the mast and removed the cotter and clevis pin from the eye terminal.  The wire was then pulled upwards through both spreader ends and then removed from the boat.  We then installed a Sta-Loc Eye terminal on the 5/16-inch spool of wire and measured it for length to cut the new wire.  The wire was cut at 44 feet 3 inches, shorter than the 46 feet estimated and purchased.  The original wire eye-to-eye length was about 45 feet 2.5 inches.  The wire with the Sta-Loc Eye terminal was then attached up the mast with new clevis and cotter pins.  The non-terminated end of the wire was then routed thru both spreader ends downward and a Sta-Loc Stud terminal was installed on the end of the wire and screwed into the new turnbuckle.  It was then installed with new 1/2 inch clevis pins.  This process was repeated for the starboard side intermediate shroud. Both port and starboard side cap shroud wires were about the same length.

Inner Forestay Shroud

• Action: To Do List item A0170 – Obtain proper hardware to mount Profurl Classis/Elite Model NC32 manual reefing-furling system per manufactures instructions.
• Action: To Do List item A0173 – Replace all turnbuckles and rigging wire.
• Completed: 19 March 2018
• Cost: $409.94

Ordered and received the following items for the inner forestay shroud:

The inner forestay shroud was encapsulated by a Profurl Classis/Elite Model NC32 manual reefing-furling system. However, the attachment of the Profurl extension plates directly to the stemhead mount hole violates the Profurl installation instructions.  The additional parts to correct this improper installation were also ordered and received as the parts table above illustrates.

The rope was removed from the reefing-furling system drum. The nuts were removed from the clevis pin at the lower attach point and the Profurl extension plates slid off allowing the reefing-furling assembly to be lifted up along the inner forestay shroud, exposing the turnbuckle, allowing it to be loosened and freed.  Next, climbed the mast and removed the upper clevis pin securing the inner forestay shroud top, and using a spare halyard rope, lowered the assembly to the ground.

The original wire eye-to-eye length was about 31 feet 2 inches.  The wire cut length was about 30 feet 4 inches.

The following pictures illustrate the connection points of the aluminum extrusions.  Each connection point was fixed with four allen head set screws.  Each connection point needed to be disassembled and split apart to feed the new 1/4-inch 316 stainless steel wire through.  It was extremely challenging to break the set screws free as they were mostly likely, previously set in place with some type of adhesive sealant.

With the Sta-Loc Eye terminal attached at the top of the wire and the new turnbuckle at the base, reassembled the aluminum extrusions and used red Loctite to secure the set screws.  The entire assemble was then hoisted aboard Indra using a halyard and the top eye terminal attached to the mast fitting with a new 1/2-inch clevis and cotter pin. The lower stemhead attach point required the existing hole to be slightly enlarged with a drill for the new 1/2-inch clevis pin to fit.

The base of the assembly was attached to the stemhead fitting with a double jaw toggle and new 1/2-inch clevis and cotter pin.  The top portion of the double jaw toggle had the threaded clevis pin and nuts attached with the Profurl extension plates; correcting the original improper installation - the Profurl reefing-furling system now had full articulation of movement minimizing stress loading of the installation.