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Replacing a Mast Head Sheave?

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Relentless View Drop Down
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    Posted: 16 November 2020 at 18:23
Iím having troubles with chaffing on the Mian Halyard and had a rigger go up to take a look.  He found that the sheave is broken.  

To replace the sheave, he wants to pull the mast.  Is this really required?  Has anyone replaced their mast head Sheave?



Rob
s/y Relentless
2015 Hanse 575
Hailing: Newport, RI
Currently: St Maarten
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samuel View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote samuel Quote  Post ReplyReply Direct Link To This Post Posted: 16 November 2020 at 21:56
yes! I had to replace the pulley on my boat but as it is in the opposite end of the size scale ( 311 ) it may not apply to you. My pulley shattered, possibly due to the fact I changed to a laminate mainsail & dynema halyard & the increased loading was too much for the plastic wheel.
I often write articles for the Practical Boat Owner magazine & one was how this happened & how I solved the problem.
Fortunately my mast was down when i had to do it but in the interim I had a temporary solution. which involved hoisting a pulley to the masthead on the halyard with another halyard through that pulley.I locked that off tight & did not move it again.  That got me through the season.
You should be able to do it from aloft if the design is similar- just heavier

Mine had a plate on the top with a division to keep the 2 pullies apart ( topping lift & halyard) This plate is non load bearing & removed by taking out 2 small bolts. It meant that the masthead light came off with it but that just hung to one side. You can see the plate, upside down, to the right in the picture
That exposes the pullies. You need to take something to hook the halyard ( possibly an old thin screwdriver with the end sharpened & bent at right angles) With this you can hook & raise the halyard up & clear of the pulley. Your one will be heavier than mine being of bigger diameter & much longer so make sure there is no weight on the bottom (coils etc) Fix this to one side out of the way.

My pulley was mounted on a stub shaft dropped into a sort of notch, or cradle, in the moulding each side of the pulley. This is independent of the topping lift pulley so the rigger could be on the topping lift with a lower halyard as a backup. You need to pull the broken pulley up with some long nosed pliers & the stub shaft will come with it. It is only dropped in place with no other means of clamping so comes up very easily.

Put the new pulley on the stub, with a drop of grease if you wish, & drop back in place then drop the halyard back on to the pulley. Replace the cap & away you go.

Problems can occur if you have any windex etc fitted to the cap which you may have to remove also i had a problem that my new pulley was wider than the old one,  I was warned about this but baulked at the exhorbitant extra cost of having it pre machined.I have a lathe so was able to skim it to size myself.
So you need to check these details when buying the replacement

You need to check with the mast supplier if what I have told you matches the design of your mast. If so there is no reason why you cannot do it. If I had another break, I would go up the mast & do it myself.
A couple of trips up is not difficult & you have decent winches to get someone up the mast & a decent bosuns chair so that you can get nice & high up against the masthead. I am fortunate that my chair does this having a chest hook that is low on my hips so I sit higher



Edited by samuel - 16 November 2020 at 22:24
Daydream Believer- Hanse 311- No GBR9917T- Bradwell Essex
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Wayne's World View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Wayne's World Quote  Post ReplyReply Direct Link To This Post Posted: 16 November 2020 at 22:18
Rob,

I think the main halyard sheath and topping lift sheath are incorporated in the insert which fits into the top of the mast. So to remove this he would need to be on held aloft on the gennacker halyard which is lower and it may be difficult to access the fittings holding the insert in. The gennacker halyard would only give him one line and no second safety line. So I can see where he may want to pull the mast. I would have thought it cheaper and less disruptive for you and Relentless to use a crane with a personnel basket to enable him to access the mast whilst the boat is alongside. I guess if you had other issues you wanted looked at/fixed or additional items like spreader lights etc fitted maybe it would be worthwhile pulling the mast. You would need a crane to pull and again to replace the mast so  the cost should be less. If you do end up pulling the mast you should look at replacing the mast gaiter whilst you have the mast out. 
Wayne W
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Black Diamond View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Black Diamond Quote  Post ReplyReply Direct Link To This Post Posted: 17 November 2020 at 01:13
Wayne answered my question,  which was "how do you replace it if you are going up the mast and putting load on it".

"SMOM" applies here.   "Small matter of money"... hiring a crane would certainly be easier, but I'm sure its going to cost.


Rick
S/V Black Diamond
Hanse 575 Build #192, Hull# 161
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Wild View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Wild Quote  Post ReplyReply Direct Link To This Post Posted: 17 November 2020 at 11:39
Hello
we have already 3-4 time's this issiue in 10 years Broken main halyard- topping lift and broken sheaves.
Selden mast have upgrade this sheaves 6 years ago, they have now a shaftbush in Iglidir instead whole composite( plastic)
 Selden Mast declare : you can replace the sheaves with out unstepping the mast this is true with a top rigging but with the Hanse fractional setup not. To pull the sheaves up and take then out you have to take off the loads of the 2 lifelines.(main and topping lift) mission impossible. the spi halyard is 2 m lower.  
Before I set up the mast in 2010, I placed 2 maststeps 1,5m lower than the masttop to avoid this problem. Standing on the steps, I remove the main halyard  and toppinglift lines from the climbing harnas put a safetybelt over the masttop section and   use the spihalyard as a second safety line, I can take off the loads of the main halyard and toppinglift line and replace the sheaves. 
This summer I broke the main halyard and a few minutes later the toppinglift. 66 years old and only the spi halyard left I decided to rent a height worker (30 m) with a rigger in Samos Greece to do the 1u30 job and paid 400,- euro.Embarrassed 
Wild and Wet
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Wild Quote  Post ReplyReply Direct Link To This Post Posted: 17 November 2020 at 12:45
Mast head Selden doc 
this is a top rigging there is no document of a fractional rigging ??
but the principe is the same.
uploads/2431/mast_top_1_2020-11-17_12-44-09.pdf

Edited by Wild - 17 November 2020 at 12:53
Wild and Wet
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Black Diamond Quote  Post ReplyReply Direct Link To This Post Posted: 17 November 2020 at 12:58
So I can assume with a 3 year old boat that I have the new sheave setup?

Honestly,  I have not checked.    Going up the mast that far is for younger types.


Rick
S/V Black Diamond
Hanse 575 Build #192, Hull# 161
Newport, RI
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Wild View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Wild Quote  Post ReplyReply Direct Link To This Post Posted: 17 November 2020 at 14:09
Rick
I am quit shure you have the new one. the last 5 years no problems any more.Thumbs Up
the old one's are out production I believe.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Mark_J1 Quote  Post ReplyReply Direct Link To This Post Posted: 17 November 2020 at 20:37
On a Sparcraft Mast on a 400 I've replaced the sheaves in situ.  It requires that for part of the operation you hang from safety strops across the top of the mast.  So not for the feint hearted :-)  I am assuming your mast is supplied by Selden from my trips on 575s?  If your rigger was able to get to the top of the mast why not send him up again and get him to fit a pair of mast steps while he's up there and D-ring on the side to attach to.  Then do the job with strop around the mast and support from the D-ring?  You may need to offer a significant beer bonus!

Mark


Edited by Mark_J1 - 17 November 2020 at 20:40
Hanse 400e "Grey Goose" Hull #31
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Relentless View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Relentless Quote  Post ReplyReply Direct Link To This Post Posted: 05 December 2020 at 11:45
we pulled the rig.  Glad that I did.  Ended up replacing 3 sheaves.  The new sheaves were custom made here with bronze bushings.  The pins were aluminum, and they were replaced with SS.  The rig is back up and the halyards run as smooth as butter!!




Rob
s/y Relentless
2015 Hanse 575
Hailing: Newport, RI
Currently: St Maarten
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