CAL35 Internal outhaul rigging

[Harmonysailor]

Hi gang- I need to replace the internal outhaul on our 1984 CAL35 with Kenyan spars. Anyone know where the forward end is secured inside the boom? I tied a messenger to what's left of the outhaul and pulled out the aft end. I suspect the forward end and block is secured to the hex bolt that doesn't (apparently) have any other purpose. I don't want to attempt disassembly of the boom fitting unless necessary.

Thanks- Dan

Outhaul sketch_IMG_20240508_145426_245.jpg (2.05 MiB) Viewed 3604 times

Outhaul2.jpg (370.08 KiB) Viewed 3604 times

[rcvesselstyn]

Hi Dan. This would be an opportunity to use one of the cheap endoscopes from Amazon. It would allow you to see the internal layout, when you could run the endoscope up it would also give you the distance measurement so you know where the fitting is located.
An alternative would be to butt end splice the outhaul, but it looks like the amount of space on the turning block would be limited.
If you really can't get the fitting on the boom off then using a combination of a couple of long rods and the endoscope it would be possible to feed the line through the fitting. Doing it this way you probably would bring the bitter end all the way out to the end of the boom and secure it there.
Just a few thoughts. There's probably a better way.
Good luck.

[Harmonysailor]

I hadn't considered this an opportunity to buy more tools but I'm all in! I think I can sew/tape the new line to the old and pull it through the pulleys. That gets me 3/4 there. Then pull the new and old back through the boom and secure the new line externally or at least accessibly. Cut the old line off as short as possible and allow whats left it to live out the rest of its days hidden inside the boom.

[rcvesselstyn]

Sounds good. The only potential problem I can foresee would be the old line getting caught on the new and jamming the block inside the boom. It would depend on where the tie off is in relationship to the block.