DaySailer.org Forum

I just acquired some Daysailer boat parts which included a Proctor gold mast and boom. The mast has an M stamped on it so I assume that is the model. The mast has been severely neglected. It had the original wire/rope halyards that run down the back of the mast track. The jib halyard pulley is frozen and busted. Since it is built into the mast, I have no way of replacing it. My plan is to replace all the halyards with rope by replacing all the upper through mast pulleys and installing new through mast pulleys at the bottom and running the halyards inside the mast. Has anyone done this before?

In the deal, I also got a complete rudder and tiller (tiller needs work) with tiller extension and a centerboard with a chrome plated handle. I'll probably sell these items, but I plan to install the mast and boom on the Daysailer I just gave my son. I also got two main sails, two jibs and a spinnaker. Out side of having rust stains from poor storage, they are not in bad shape.

Pictures? I'm not familiar with the way these masts are set up, so a picture may make it easier to follow.

Image 1 is the mast head pulley for the main wire halyard. Image 2 is the corroded pulley for the jib halyard. Above the jib halyard is a hole for the spinnaker halyard I believe. The last image is the mast base which I have to find a way to hold it in place in the boat.

I take it the center picture shows the jib halyard exit at the top. Did the design use a double sheave with the outer one removed and the inner gloriously corroded in place? The small circular hole above, is that for attaching the forestay? Or does the luff of your jib replace the forestay, and the hole is for the spinnaker?

I have no idea how one would go about removing the stuck pulley. I wonder what holds it in place? There's no visible bolt, nor would there be access to the fixture from the inside. Could it be just a "press fit" relying on the angled slot for the two SS tangs to be pulled into place when tension is applied? In that case, a hacksaw cut of the pulley might free up the pieces for removal.

You could convert the jib halyard to an external one, by simply using the remaining parts of the fixture as a strong point, but I gather that's not your intent.

The Rhodes 19 mast is similar to the Day Sailer mast and uses internal halyards. the jib halyard sheave box looks similar to the one in your center picture. Attached is a picture of the R19 jib halyard sheave box. Stuart Marine has this part for early R19s. They may also just sell the sheave.

John

The forestay attaches to the fitting just above the corroded pulley. I think the hole above was for the spinnaker halyard, but who knows how. For the jib halyard, I'm going to try and dig out the old pulley and replace it. If that doesn't work, I'll install a thru deck pulley. The other challenge is finding a mast step that works with this base. Maybe the standard DS mast step.

Nothing is ever easy.

Roger,
Rebuilt/Restored an old gold Proctor Mast last year and can fill you in on the process.
Send me your current e-mail address as you should have my e-mail address from previous e-mails.
Mike Gillum DS#2772 BUBBA

Dwyer makes mast steps for different size masts. Here is the link https://www.dwyermast.com/families.asp? ... Name=Masts.

Hi Mike

My email address is public knowledge, rlivingston43@gmail.com .

I appreciate the help.

Roger

After about 6 weeks of work, I finished the old Proctor mast and boom. I first had to cut out the old jib halyard sheave box and weld a plate over the hole. We also welded a lot of unwanted holes in the mast.



Next I cut openings for the new jib halyard sheave and the exit sheaves for the halyards. The mast and boom looked terrible so I decided to paint. Lots of sanding and two coats or Rustoleum self etching primer and four coats of Rustoleum Professional gloss enamel and the mast and boom was done. I replaced the mast and boom on old 2444...a DS1 I restored and is now being sailed and raced by my son Tom. As with all my projects, it took me three times longer than planned and cost twice as much.