So I was concerned that the lines were seeing more friction than before and decided to take off the "tunnel covers" that run down each side of the boat.   Sure enough,  the sheaves were turning with a lot of effort and it really took the winches to move the lines thru the system.   The mainsheet, for example,  could not be pulled thru by hand except when there was really a lot of slack in the system.

OK...  so break out the tools to remove and lubricate the sheaves.    

Still not really doing the job.   Called my rigger for his advice and he tells me the Spinlock T50's (asymetrical) that are on the system are undersized for the boat, and running 14MM halyards and sheets thru them along with membrane sails and the loads expected is a problem.    Its interesting that Hanse put the T50 on the boat, but had the higher strength alloy sheaves.  It doesn't come this way.  Normally it ships with the composite sheaves, which are less strong.   They must have known it was marginal. The base SWL for the T50 is 1650lbs.  

I'm looking at options to address this, and it seems like the following list:

1.  Just replace the sheaves and hope for the best.    These are about US$30 each and it would take 5 per side so about US$350 in total.  I might get a season or two of improved use before these failed as well. Same SWL to be expected). 

2.  Replace the T50 with a "high load" Spinlock T50.   This has a slightly stronger frame and the alloy sheaves.   It has the advantage of using the same drill holes (56mm) but needs one more hole to be drilled.    This improves the SWL to about 2650lbs (per sheave) and strengthens the frame so it would likely not distort causing sheave damage. This ends up costing about $400 each side but you get a stronger setup for about twice the money of (1) above. 

3.  Replace the T50 with a Harken Big Boat organizer.   This requires drilling and tapping new holes, but the SWL moves to about 4600lbs per sheave and my rigger tells me this will run nicely and address the problem properly.   Unfortunately, these organizers cost about US$1000 each, so its an expensive option.   

One of the things I am worried about is fitting it between the ends of the tunnel cover.  If you see the current setup, its close to the edges and something needing more real estate might not work.  

See pics of the three below...

The current T50 (Asymetrical)

This is the "high load" version of the Spinlock T50 (same drill pattern, one more hole)

This is the Harken Big Boat 5 sheave setup.     New everything.   New drill pattern,  need to check overall length a bit more. 

Has anyone else done this upgrade?   What did you do?

I have replaced our deck organisors twice. Once with the same T50A and once with the T50 high load units. I am not holding high hopes the T50HL units will cope. You are correct the organisors are undersized for the loads. 

The frustrating part is that for the cost of the Harken I can replace the T50A (as you did) with the high load unit twice.     If it buys me 4 years, that's probably OK.     On the other hand,  I really hate doing things like this wrong.    I've always tried to replace items with the properly sized or appropriate part. 

Still researching.

Please keep us informed when you decide on your fix. 

We only have 143,5 square meter sail (main 87 and self tacking gib 56,5) on a 545 e build 2010(early building number)and have the Spinlock T50 reinforced type standard build in and with our new membrane sails they are on the border off there limits.

Economization I suppose?

We try to replace then by Harken big boat 5 but have not enough space and the line shaves against the corners of the canal.🤬

Not sure if the 545 has the same tunnel sizing as the 575.      If you look at the picture, its possible that 14" (355mm) could be supported, but the Harken 5 sheave system requires 15" according to one web page I saw.   Another says 11 is all that is needed. 

At this point,   I'm leaning to the decision Wayne made (the high load Spinlock system).  While it doesn't have the working load of the Harken system, it does have double the strength of the current setup.    If it hangs in there for at least 2 years, I guess I can live with that result.   The Harken setup is expensive. 

This is the current TC50-A Spinlock on the boat.     The heavy loads appear to have distorted it and the sheaves have failed.  Just replacing the sheaves costs more than half the cost of the high load unit, so that doesn't seem smart. 

As you can see there is about 13 1/2" available.     This translates to about 344mm.   

Here are the specs for the Spinlock high load option.

The existing holes can be re-used as the drill pattern is the same.   That said, one more hole seems required in addition to what is there.   The overall length is 336mm. 

I am speaking with the Harken people tomorrow (not much over the weekend) as they seem to have conflicting information on diagrams and web pages.   One says the Harken organizer is 15" long.  The other says 11.something inches long.     One might work. The other clearly won't.    

When I find out, I'll post the results and final decision here. 

When you talk about drilling a new hole, you also mean to bury a nut inside? forces will be significant...and they cumulate - multiple ropes could carry a load.

please keep me posted in case you find a good solution, Rick.

from what I can tell, there is no good solution.

1.   The harken big boat system  (which would be sized properly) is too big to fit in the available space.   15" when you have 14"

2.   The high load spinlock system is also too long, and those that have used it have had to cut off the end to make it fit.  This does get rid of the extra hole.   To answer the question asked:  the extra hole is because the asymetrical T50-5 has 5 drill holes and the high load variant has six (due to the end also being secured).

3.   I've looked at other brands (ANTAL, LEWMAR, SCHAEFER, etc.).   None seem to fit in the tunnel provided or have any improvement in SWL over the spinlock.

4.   Even replacing it like-for-like has its problems.   From the factory, HANSE put the TC50-5A (Asymetrical) on the boat.   

a.    If you accept the fact that you might have to replace the unit every two years (less or more depending upon how you sail),   then this might be an option.  The Harken system is US$1000 each and the Spinlock TC50 can be found for US$120 each.   Quite a difference.  

b.  If you buy that today, however, it comes with the black acetal sheaves and not the higher load carrying alloy sheaves.    You need to upgrade the new unit by replacing all the sheaves.   With 5 on each side (6 on some of your boats), and a cost of US$34 per sheave, this takes a $120 fully functioning organizer and raises its cost $300.   Times two for both sides.   Still better, but worth noting. 

I've looked at "stacking" options as well, but the tunnel complicates that.  There just isn't the vertical space available to do this.   If someone has made this work, I'd like to know, but for now I am sticking to single level line organizers.

Still checking out options, but they seem limited to the above.  

The 50/5 asymmetric type is only available in T version with acetal sheaves and not in the stronger TC version.in the T version you have to buy extra alloy sheaves to replace the acetal ones.

***and*** you would have the acetal sheaves as spares.   

no it was identical to the one installed, including the sheaves. it's already in place...

Decision.

There really is no other decision possible.     I've researched all the options and a like-for-like replacement is really the only alternative that works.    

1.  The Harken does not fit.

2.  The high load version of the T50 requires that you immediately cut the ends off to make it fit.

3.  None of the other brands (lewmar, selden, schaefer, etc.) have any improvement in safe working load. 

So...   I've purchased replacements of the T50 (Asymetric) as well as the alloy sheaves to give it some additional strength.    

This option has the benefit of just using the same bolts and tapped holes and not having to drill a new hole pattern or hire a rigger.   What I have heard from many is that you can get a few years out of this before they too (inevitably) fail.    My guess is that will be enough.  

maybe there's is a way to modify the original part and make it more robust. for example , adding a plate ...the problem in my case is related to its asymmetric nature: the axes bent , locking the sheaves ...

That's what I am doing by adding the high load sheaves to a part which doesn't have them.   Just as Hanse did.   

The only other thing that could be done is to buy the high load variant which, in addition to the high load sheaves) seems to have a stronger frame with bars above *AND* below the sheaves.   Unfortunately, to make it fit you need to cut off the end which probably negates about 50% of the additional strength as well as voids any warranty. 

Obviously, this doesn't solve the problem.  It just buys some time til the next failure. 

The basic issue is that the frame *AND* sheaves (even the high load ones) are undersized for the boat, especially when you have membrane sails and high tech halyards.   

Its complicated by the size of the tunnel, which restricts the length of any potential replacement organizer.   You can also replace the current setup 2-3 times and still spend less money than buying something like the Harken unit (if it fit)...

I'm bringing a few of the acetal sheaves as spares just in case something happens down the road and I need a quick fix.

You need to transform the bottom into the top.   

Pop off the pressed in fitting,  put the new sheave in place and then press on the washer again (not so easy without the right tools). 

The finished product.    Mounting is easy given that they use the same holes.  

We are about 280nmiles from Samoa after leave Bora Bora about 910nmiles in our wake. We had some suitable winds this morning to put up the full rig and of course the sheath in the deck organiser for the main halyard self destructed. I will try to get the aluminum replacement sheaths sent up to Fiji so I can replace all the plastic ones. Fiji will be our next destination after a few weeks in Samoa. Do you know the Selden part number for the aluminum sheaths? I can probably get them sent to Fiji from NZ or Aust. The good news is nothing else has broken. 

The aluminum sheaves and the organizer are Spinlock, not Selden.   At least the ones installed on my 575.     The part number is SPIT50-A and I needed 10 of them to upgrade the sheaves (my organizers are 5 per side)   Are yours Spinlock or Selden?

I got mine from Vela sailing supply but my guess is there is someplace closer with less air freight cost. 

Just an update - I had the old organiser which I replaced in St Martin in early 2022. I have prized off the sheath washers which was easier than I thought it would be. When we get to Samoa I will the replace the smashed sheath for the 600nmile trip to Fiji. I will still replace the sheaths with the aluminum ones once in Fiji.  

Found all the info I need. Looks like I can get the ali sheaths from New Zealand and have them delivered to Fiji. The joys of boating. Doing repairs in exotic locations. 

You are correct they are Spinlock - it must be the lack of sleep over the last 8 days in transit. Velo only had 2 in stock. Yet to hear back from a NZ supplier and and Aussie supplier about stock. Thanks for the help. 

Let me guess.   Some other 575 owner cleaned out their stock recently? :-)

It probably stretches the definition of PRIME delivery,  but AMAZON has them on their web site.

That's a good point.    I spoke with SPINLOCK just to be sure of the process for swapping, and they told me that they USUALLY do not make the whole unit available with aluminum sheaves, but they can do it when asked.   You just need to go to SPINLOCK directly.  That's how HANSE (and I assume Boattoon) got theirs.   Most retailers don't have it.  In my case,  I found that the cost of the unit from Boatoon and SPINLOCK was much more than just buying the sheaves separately and swapping. 

If your frames are in good shape, then I would think swapping the sheaves is all you need to do.   If they are deformed in any way, then maybe that makes sense.

I was told by boatoon in a different context that they sell parts from the Hanse inventory. it makes sense, and indeed explains why they always have the "right " part that's installed on the boat.