Do it! Weather it works out or not, if you are willing to put in the effort I will be interested to see the results. Sometimes with a bit of tweaking you can make something work that other don't think will. I have to use my retractable boarding ladder as an example. A lot of people were skeptical that it could be made to work given the limited options and places to attach and store it. But I found a ladder that could be made to work, MacGyvered the install and now I don't know how I lived without it.
Thanks Golfdad I missed that! Note that the line sold at hardware stores is not very strong and extremely flexible. And the bungee cord is really low quality - will likely not last you a full season. I know it sounds kind of silly but you are better off purchasing the running rigging from a reputable marine store. There is nothing worse than your 40' mainsheet stretching out to 60' in a gale. I've seen it, get some of that stuff wet and try and sail with it, bad scene!
I would suggest using a relatively cheap low stretch poly line for all your lines - New England Sta-set is the standard. I buy all my line from Annapolis Performance Sailing, they have the best line selection and prices in the business. Not to mention some of the best customer service! Here is their line section
http://www.apsltd.com/c-1485-line.aspx They also have high quality shock cord at the bottom.
The best part though is thier sail line section here:
http://www.apsltd.com/c-4751-line.aspx I outfitted my whole boat with dyneema and vectran line for the same price as poly from this page.
Stock lengths for running rigging can be found here
http://www.kosailing.com/…brand_pdfs/catalog_4.pdf
Also not that tying bungee/shock cord is a bad idea. The knots tend to work themselves loose very quickly (regardless of how you tie them it seems). You should use hog rings and hog ring pliers to secure bungee.
Cheap hog ring pliers:
http://www.harborfreight.…og-ring-pliers-3102.html
Hog rings
http://www.apsltd.com/p-8…s-for-14-shock-cord.aspx, or you can buy them induvidually at your local Grainger. That is also a good source for stainless rivets.
Finally here's the best trick for finishing the ends of tech line that doesn't melt, covering hog rings so they won't scratch or covering other sharp edges on wire rigging. Electrical Polyolefin heat shrink tube with hot glue inside
http://www.harborfreight.…shrink-tubing-67598.html. It shrinks 3:1 (not 2:1 like regular heat shrink) and glues itself to the line. A $10 assortment will last you the rest of your life.
As far as standing rigging, if you know how old the rigging is, that it was run in fresh water only, have run your hand down every piece of the rigging without snagging a loose wire, inspected every inch for corrosion or crimps and found that it is all right I would maybe trust it for a season or two (with consenting adults only only the boat). Especially if it is less than 10 years old. However most boats of this vintage are sold with the original rigging, 30+years old. Even standing in the yard all the time the wire will degrade somewhat. I was pretty lucky, I ran my boat this way for a season and didn't dismast. Then I accidentally dropped my mast the next season while adjusting the rigging, saw what it could do and scared myself into buying new rigging.
I would suggest just going with the rigging packages offered by Murray's Marine or Salty Dog Marine. Those are easier, very likely cheaper and definitely more secure than making them yourself. If you are sailing in salt water, strip the PVC coating off so you can see any corrosion. If you are sailing only in fresh water, you can leave it on and just inspect the fittings periodically. Fresh water won't do much to the PVC coated wire, but the fittings are in contact and made up of dissimilar metals so they can corrode over time. Once you have replaced the wire rigging, make note of it. Replace again every 5-7 years (5 years for sure in salt) weather they look bad or not. Having a mast drop on you while sailing isn't something you ever want to expereince. Hopefully it will drop away from the boat but depending on how it occurs it is equally likely that it will drop backwards onto you. Especially if the forstay or a bridle lets go!
If you really want to make them yourself the cheapest way is with a swage it tool.
http://www.apsltd.com/c-1…ng-tool-by-swage-it.aspx Buy the big one! Your rigging is 5/32" dia and the small one won't work for that. Copper with zinc plating nicopress fittings (use 2 per end on each wire, don't trust 1). Use stainless thimbles at each fitting. Not sure where you can get the stainless wire cheap, maybe a local aerospace manufacturer? Remember that the key to the nicopress fitting is to compress the copper into the wire strandes so they essentially bond together. You can also get non-swaged sta-lok fittings that are just as secure but they are extremely expensive at about $50 per fitting.
Wow, now that's a post. I think everyone is now hoping I go back on vacation soon. :)
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Dave Bonin
1981 Nacra 5.2 "Lucile"
1986 Nacra 5.7 "Belle"
Winnipeg, Manitoba, Canada
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