Initial Inspection - Running Rigging

 

Winches

Indra has ten winches installed aboard; two Lewmar and eight Custom Yachts LTD.  No spare winch parts, manuals, or servicing materials were located aboard.

The two Lewar winches are, non self tailing, chrome standard winches, size 16, two speed, P/N: 49016032 and are still available for purchase, along with spare parts.  The Lewmar winch manual was available and downloaded from the Lewmar website.

The eight Custom Yachts LTD winches have issues - was not able to find a manufacture's website, manuals, etc.  Internet searches revealed these winches were used on many Asian built boats but not much else.  A few sites hinted that these winches were similar to Barient or Barlow winches, however these manufactures also no longer exist.  All the Custom Yachts LTD winches are non self tailing winches.  The prospect of not being able to source basic spare parts, pawls and springs, might drive the need to replace these winches.

The previous owners log entries on winches listed March 2014 as "Dirty" with prior entry of November 2010 as "Checked" - not very informative or indicative of regular maintenance.  A turn of each winch revealed they did turn, some not as easily as expected; probably indicating problems internally or servicing was needed - corrosion of exterior surfaces was present on most.   Most of the major winch manufactures provide guidance on recommended servicing of their winches.  Most recommended servicing at the beginning and end of the sailing season (sailing season is conveniently not defined). On active sailboats, they generally recommended quarterly or more often if extensively used.  So generally it appears the interval for cleaning, inspecting, greasing, and oiling winches should be two to four times a year - all at the owner's judgement/decision.  All of Indra's winches were neglected and long overdue servicing - added to the To Do List was to service winches after obtaining winch grease, oil, pawls, and pawl springs.  How and where to obtain any parts for the Custom Yachts LTD winches remains an unknown.

The next question on the winches was - are they the "right" size for their intended use and placement.  To determine a possible answer to this, used the winch selection guides available on the internet for Lewmar, Harkin, and Anderson winches.  Based on the commonality of winch number systems, assumed that the Custom Yachts LTD winches followed the same pattern - that a #16 winch would have a approximately 16 to 1 power ratio.

Boat Length 35 ft/ 10.4 m Winch Manufacture
Area Custom Yachts Lewmar Harkin Anderson
Jib Sheet 277 sq ft 26 40 50 40
Jib Halyard 26 sq m 16 30 32 28
Staysail Sheet 129 sq ft 16/22 15 20 18
Staysail Halyard 12.5 sq m 16 15 16 18
Spinnaker Sheet 485 sq ft 16 40 46 28
Spinnaker Halyard 45 sq m 16 8 32 18
Main Sheet 315 sq ft 16 15 40 28
Main Halyard 29.5 sqm 16 15 32 18

 

 

Based on manufacture recommendations, it would appear that some of Indra's current winches are under powered for their intended use.  A disadvantage of Indra's winches is they are all not self tailing models.  An additional consideration prior to a possible replacement is can all crew members (wife and daughter) tighten the lines without significant strain - this can only be determined though actual use at future date - use of a longer winch handle to add leverage is also a consideration.

1.  A Custom Yachts LTD 316 SS #16 winch is located on the port side of companionway entrance under the hard top.  This winch has lines routed to it from the port side staysail sheet and the boom vang control line.  There is provisions for one more line that is not utilized at this time.

2.  A Custom Yachts LTD 316 SS #22 winch is located on the starboard side of companionway entrance under the hard top.  This winch has lines routed to it from the starboard side staysail sheet and the outhaul control line.  There is provisions for one more line that is not utilized at this time.

3.  A Custom Yachts LTD 316 SS #26 winch is located on the forward port side of cockpit area.  This winch has one line routed to it from the port side jib sheet.

4.  A Lewmar Standard Ocean #16 winch is located on the aft port side of cockpit area.  This winch has lines routed to it for the jib and staysail furler control line and main sheet traveler port side line.

5.  A Custom Yachts LTD 316 SS #26 winch is located on the forward starboard side of cockpit area.  This winch has one line routed to it from the starboard side jib sheet.

6.  A Lewmar Standard Ocean #16 winch is located on the aft starboard side of cockpit area.  This winch has one line routed to it for the main sheet traveler starboard side line.

7.  A Custom Yachts LTD 316 SS #10H winch is located on the starboard side of boom, approximately three feet aft of the mast.  It is suspected this winch is used for a reef line and the topping lift line.

8.  A Custom Yachts LTD 316 SS #16 winch is located on the starboard side of mast, approximately two feet from base of mast.  This winch is used to tighten halyard lines.

9.  A Custom Yachts LTD 316 SS #16 winch is located on the port side of mast, approximately two feet from base of mast.  This winch is used to tighten halyard lines.

10.  A Custom Yachts LTD 316 SS #16 winch is located on the port side of mast, approximately three feet from base of mast.  This winch is used to tighten halyard lines.

Added to the To Do List:

  • A0208 – Obtain winch grease, oil, cleaning solvent, stainless steel cleaner, spare pawls, and spare pawl springs.
  • A0209 - Inspect, clean, grease, and oil all winches.
  • B0210 - Determine winch replacement priority with self tailing winches.

Mainsail Traveler

7/16 inch line
Ronstan—Series 60 All Purpose Stainless Steel Cheeked Blocks recall dated January 2006 was applicable to RF1158 Double Block Cam Becket and are Manufacturer Discontinued
Ronstan I-Beam Traveller System Series 32mm Car P/N: RC63214
Ronstan I-Beam Traveller System Series 32mm Track P/N: RC6320-1.0

Mainsail Sheet

Outhaul System

The outhaul system is used to extend the foot of the mainsail along the length of the boom by attachments at the clew.   Indra's mainsail is loose footed, the foot of the sail is only attached to the 18 foot boom at the tack and clew.

The outhaul rigging begins at the end of the boom where a stainless steel eyestrap is attached with two stainless steel screws.  A 1/8 inch wire thimble encases 1/8 inch, 7 x19, 304 stainless steel wire which is secured with a compression sleeve; and is attached under the eyestrap.  The 1/8 inch wire runs forward and is routed through a 1.5 inch sheave mounted on the forward side of the outhaul clew car of undetermined manufacture.  The outhaul clew car rides on a 1.25 inch wide by 3/16 inch thick, stainless steel T-track which is approximately 1.5 feet in length.  The mainsail clew ring is held onto the outhaul clew car by a 3/8 inch wide by 1.25 inch long clevis pin and secured with a 1 inch long cotter pin.  The 1/8 inch wire is then run aft from the outhaul clew car sheave and enters the boom through a Ronstan stainless steel exit block, part number RF456, with a stainless steel 1.75 inch outside diameter and 3/8 inch wide sheave for steel wire use of 7/32 inch maximum size. The Ronstan RF456 exit block is mounted in a boom cutout 2.5 inch long by 9/16 inch wide and extends down 1 5/8 inch internally. It's exterior top measurement is 2.5 inch long by 1.5 inch and mounts with six #10 (3/16 inch) fasteners.  The Ronstan RF456 exit block is discontinued and no longer made by Ronstan.  The 1/8 inch wire then runs forward, internal to the boom, from the Ronstan RF456 exit block.  The 1/8 inch wire is spliced to 3/8 inch double braid rope at some position internal to the boom.

Inspection of the outhaul clew car clevis pin revealed it is worn from contact with the mainsail clew ring;  a replacement and spare clevis pin with cotter pins will be ordered.

The 1/8 inch wire to 3/8 inch double braid line exits the forward bottom side of the boom on a 1.7 inch sheave.  There are three sheaves at forward bottom side of the boom, with only one currently utilized.  The 3/8 inch double braid line is routed to the base of the mast and routed through a Schaefer Marine 3 Series Single Sheave Block for use with a maximum size 7/16 inch rope.  The 3/8 inch double braid line is routed aft on the starboard side through a Ronstan (unknown part number) and FICO Australia part number FG1233, double sheave deck organizers.  The FICO (Field Instrument COmpany) was bought out by Ronstan and no longer exists.  The FICO double sheave deck organizer is 5.5 inch long by 2 inch wide by 1 1/8 inch high; and is attached to the deck with two 1/4 inch (6mm) screws on 2 1/4 inch centers.  The aluminum sheaves are 1 7/8 inch diameter by 13/16 inch wide; and are suitable for use with up to 5/8 inch size rope.  The 3/8 inch double braid line is routed aft through a hole in the starboard, front side of the solid fiberglass dodger to a Spinlock Powerclutch part number XAS0612/2.  A Custom Yachts LTD 316 SS #22 winch is mounted close by to assist in the tightening of the outhaul line.

Added to the To Do List:

  • B0204 – Obtain replacement and spare outhaul car 3/8 inch x 1.25 inch long clevis pin with 1 inch cotter pin.
  • B0205 - Obtain replacement 1/8 inch wire to 3/8 inch double braid outhaul halyard.

Boom Vang System

A boom vang system is usually a line connected at the base of mast to a position on the boom intended to exert a downward force on the boom to control the shape of the sail.  On Indra, the boom vang bail is attached approximately 5 feet aft of the mast.  The bail is custom made of stainless steel with a base 5 inch by 2 inch wide affixed in three places with rivets on each side of the boom.  A 3/8 inch bar of stainless steel is bent into a u-shape and attached to bases by welds.

Attached to the bail is a Harken 3 inch Double Sheave block, which relays 7/16 inch double braid rope to a Schaefer Marine 3 Series Double Sheave Block, with the beginning of the rope attached to the deck with a cast stainless steel diamond shape pad eye.  This setup results in a boom vang system with 4 to 1 purchase.

The 7/16 inch double braid line is routed aft along the port side from the block attached at the base of the mast through two FICO Australia, part number FG1233, double sheave deck organizers.  The 7/16 inch double braid line is routed aft through a hole in the port, front side of the solid fiberglass dodger to a Spinlock Powerclutch part number XAS0612/2.  A Custom Yachts LTD 316 SS #16 winch is mounted close by to assist in the tightening of the boom vang line.

Added to the To Do List:

  • B0206 – Obtain replacement boom vang 7/16 inch double braid rope.

Topping Lift

The topping lift is usually a line attached at the end of the boom and connected at point near the top of the mast whose purpose is to apply an upward force on a boom and hold the boom up when the sail is lowered.  On Indra, the aft end of the 18 foot boom is cradled in a boom gallows and the topping lift is tensioned to lift the end of boom out of this teak wood support.
On Indra, the topping lift is attached at the masthead with a 1/4 inch stainless steel bow shackle with screw pin (Suncor Stainless S0116-0006) that was not secured with safety wire.  The bow shackle connects to a rope eye splice made of 5/16 inch double braid rope that that extends 3/4 the way down to the end of the boom and is attached to single sheave block of unknown manufacture, suspect block is a Schaefer Marine 3 Series Single Sheave Block with Swivel Shackle 303-05.  This block is encased in a worn out leather covering providing UV and sail chafe protection that needs to be replaced.

The second topping lift line begins at the end of the boom were a angled steel bracket is attached to the boom with a bolt.  A 5/16 inch double braid rope eye splice is attached to the bracket with a 1/4 inch stainless steel bow shackle with screw pin (Suncor Stainless S0116-0006) that was not secured with safety wire.  The 5/16 inch double braid rope extends upwards, is routed through the Schaefer Marine 3 Series Single Sheave Block with Swivel Shackle (303-05), and then routed back down to the starboard side end of the boom to a Schaefer Marine 3 Series Single Sheave Block with Curved Stainless Steel Base (303-30), secured to the boom with four #10 (5mm) screws.

The second topping lift line is routed about 2 feet forward and is terminated in a rope eye splice and attached to a Schaefer Marine 3 Series Single Sheave Block with Becket (303-13).  A third topping lift 5/16 inch line is formed to a rope eye splice on one end attached to the becket of the Schaefer Marine 3 Series Single Sheave Block with Becket (303-13) and then routed forward, about 12 feet from aft of boom, around a Schaefer Marine 3 Series Single Sheave Block with Flat Base (303-09) mounted to the boom on a flat base cheek pad and secured with four #10 (5mm) bolts.  The third topping lift 5/16 inch line is then routed back aft along the boom and wraps around the sheave on the Schaefer Marine 3 Series Single Sheave Block with Becket (303-13).  The third topping lift 5/16 inch line is then routed back forward approximately 16.5 feet from aft of boom to a RC Marine Products Company Ltd (no longer in business) 5 inch composite cleat and tied off.

The following diagram illustrates the layout of the topping lift components.

After extensive internet research, decided to adopt a simpler topping lift design that utilizes a halyard attached at the masthead and connected to the end of the boom; and would have it's control line run to the base of the mast, then aft to the cockpit.  The majority of the components to implement this change are already installed.  This change has the additional advantage of providing a spare halyard in the event it is needed.

Added to the To Do List:

  • B0207 – Redesign and install topping lift masthead halyard with control lines run aft to cockpit.

Lazy Jacks

Jib Control Lines

Jib Furling Line:  The 5/16 inch double braid rope (white with one red fleck) exits the Profurl Basic Model B35M manual reefing-furling system.

Jib Sheet - Port Side: 
Jib Sheet - Starboard Side: 
Jib Reefing-Furling System Rigging Problems:

Staysail Control Lines

Staysail Furling Line:  The 5/16 inch double braid rope (white with 3 blue flecks) exits the Profurl Classis/Elite Model NC32 manual reefing-furling system drum and is routed through a Ronstan Series 30mm high load single sheave block (RF30100HL) attached to the port side bow spirit stanchion.  Moving aft the 5/16 inch double braid rope is routed through a Ronstan stanchion block (RF3), made for 25mm (1 inch) diameter stanchions with 20mm (3/4 inch) ball bearing sheave for up to 12mm (1/2 inch) line, attached to the next lifeline stanchion.  At the next stanchion aft the 5/16 inch double braid rope is routed through a Ronstan Series 30mm 2-axis shackle head double sheave block (RF30202 - Discontinued).  At the next stanchion aft the 5/16 inch double braid rope is routed through the stanchion base metal support brace, continues aft along the port side cockpit coaming, and is secured on a cleat attached to the port cockpit coaming wall.

Staysail Sheet - Port Side: 

Staysail Sheet - Starboard Side: 

500mm (19.7 inch) of Ronstan Series 32mm anodized aluminum alloy T-Track (RC7320-1.0S) with black nylon ends (RC73280) secured with seven 6mm (1/4 inch) countersunk fasteners.
Ronstan Series 32mm spring loaded block on slide with stop (RF874 - Discontinued)
Ronstan stanchion block (RF3) made for  25mm (1 inch) diameter stanchion with 20mm (3/4 inch) ball bearing sheave for up to 12mm (1/2 inch) line.

Staysail Halyard:  A Schaefer Marine investment cast stainless steel shackle with 7/16 inch (11 mm) screw pin (93-75) is connected to the Profurl Classis/Elite Model NC32 manual reefing-furling system swivel plate ring; the screw pin was not secured with wire.  The 7/16 inch double braid rope enters the forward side of the mast at a approximate height of 28 feet through a sheave exit block (RF51712).  The 7/16 inch double braid rope routes internally down the mast and exits at the port side of the mast at a height of approximately 6 feet where it is secured to a cleat at a height of about 3 feet.

Staysail Rigging Problems:

Added to the To Do List:

  • B0000 – Redesign and install topping lift masthead halyard with control lines run aft to cockpit.

Whisker Pole Control Lines