how to attach new halyard end cap to mast?

Discussion in 'Sunfish Talk' started by jleguy, Jun 19, 2016.

  1. jleguy

    jleguy New Member

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    I was having a great sail today and on what was going to be my last tack of the day to head in and my halyard end cap blew out and I had to paddle in. I ordered a new one and was wondering the best way to fasten/secure the halyard end cap?
     
  2. fhhuber

    fhhuber Member

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    Just pressed in place.
     
  3. beldar boathead

    beldar boathead Well-Known Member

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    While that might work as the halyard is pulling down on the cap and would tend to hold it in place, that is not how they come from the factory, and I STRONGLY advise against sailing with it just pressed in place. From the factory, they have either come with small stainless pins pushed thru the aluminum into the plastic cap, or with two aluminum pop rivets holding it on from opposite sides of the mast. I bet yours has the pins - take a careful look. You can drive them out with a hammer and a small nail. When you get the the new cap, drill holes smaller than the pin diameter, then drive the pins thru the existing holes in the aluminum into the holes you drilled in the cap.
     
  4. jleguy

    jleguy New Member

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    Thx Beldar, and there you have it, I found a fragment of a pin in the mast when I got back and the holes for it in the halyard end cap were ripped. My guess is just old age.

    Will 1/8" rivets do it?
     
  5. Light and Variable Winds

    Light and Variable Winds Well-Known Member

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    Yes, but pop-rivets "draw up" really tight. Little force is needed to keep the cap on.

    I'd squeeze the rivet gun until some resistance is felt, then cut and grind off the mandrel. (Go no further than step #2, below).

    [​IMG]

    The force from the rivet can split the plastic, then you'll risk losing the piece again. :(
     
  6. jleguy

    jleguy New Member

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    Tutorial much appreciated!
     
  7. oldpaint

    oldpaint Active Member

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    While you have the endcap off check that there is still an intact cork or other stopper near the top of the mast. The mast needs to be waterproof so it'll will float when capsized and resist turtleling. A racketball makes a great stopper. You also might want to take of the mast bottom cap and check the stopper there. (The racketball tip originally came from Beldar. I used it on my mast.)
     
    Last edited: Jun 20, 2016
  8. jleguy

    jleguy New Member

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    This forum is great...appreciate all the tips!
     
  9. jleguy

    jleguy New Member

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    OK, I have pop rivets, rivet gun, drill, new halyard end cap from intensity sail (...which is much beefier than the old one that below out. The rim that goes into the mast is substantially thicker. It looks like it can take a full squeeze of the rivet gun, but I'll heed Light and Variables Winds' advice on going easy with that), racquet balls to replace the missing corks. To the beach tomorrow for the repair and hopefully sailing again by high tide at about noon. I'm also gong to slap little 4200 of 5200 on the end cap, figure it can't hurt. Will post results.
     
  10. jaas75

    jaas75 Member

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    remember 5200 is a forever bond so i wouldnt use it (hard to take out if you ever need to change the cap again)
     
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  11. beldar boathead

    beldar boathead Well-Known Member

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    I second the "no 5200."
     
  12. mixmkr

    mixmkr Active Member

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    With a heat gun you can remove parts installed with 5200. But I agree, no compelling reasons to use it on a Sunfish.
     
  13. jleguy

    jleguy New Member

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    So, trying to follow all the advise given above, I bought new upper and lower mast boom end caps, replaced the old corks with racket balls and used both pop rivets and pins to secure the end caps along with a little 4200. I've been up and running since the weekend before last. But I think it is time for a new mast. It's got at least one pinhole you can't see but I found it when I rinsed the inside before reassembling with racket balls and end caps and saw some water piddle out.
     
  14. Charles Howard

    Charles Howard Member

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    It is hard to get them water tight. A lot of sailors have a hole drilled in the center of the bottom cap to allow draining at the end of the day.
     
  15. Light and Variable Winds

    Light and Variable Winds Well-Known Member

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    You won't believe what shipping a new mast costs!

    I've repaired my broken mast, and although it's heavy, I'd sell it for $40. But shipping it would be unreal! You'd want to pick it up from here.

    Put a glob of silicone sealer where the pinhole is, then spray WD-40 inside before resealing, would be my suggestion.
     
  16. Wavedancer

    Wavedancer Upside down? Staff Member

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    Just cover the pinhole with tape would be my (lazy man) solution...
     
  17. beldar boathead

    beldar boathead Well-Known Member

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    I'd wait for the mast to break before getting a new one. And it may never snap.
     
  18. jleguy

    jleguy New Member

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    Sounds like my work on my mast is done...
     

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