[quote=theblackpearl]Thank you all for your insight. I have been thinking more about the main on the ocean situation, and I think the problem may not be my strength vs. friction to raise the sail, but rather the ring getting caught on the bottom of the hook as the mast rotates around while in irons in the waves. So no amount of strength is going to fix the issue, it becomes about technique. I purchased a halyard puller, and I am going to anchor in the sound (without my wife!) and practice to see if I can figure out a better process.
The reinforcement does appear to have made the rudders slightly too wide, especially on the starboard side. They still lock down, but there is some noticeable bend to the casting that could be corrected with your method.
I'm currently on the fence with the rudder repair. I can sand down the rudders, and rebuild the assembly with new springs etc. and keep my fingers crossed that works. Removing the catch bolt might be a challenge as it is epoxied in, but a drill press should be able to take care of it. Less than a $100.00 fix, but have less confidence that it will be effective and quite a bit of time (precious with three young children).
I can invest in the new MX blades and gudgeons as well as all new assembly hardware, and fix it properly but at an expense of close to $900.00.
Third option would be to install a quick release clamcleat on the top of the tiller arm. Says you can set resistance to over 500lb, and it will still break away if you hit something. While this is the easiest, and guaranteed to work, I feel like its also a work around. I also fear that when the rudder does pop (as this doesn't address the root cause just the symptom), no matter how tight you cam the rope, weather helm will still develop due to stretch in the line. Certainly not to the extent as when the rudder is up, but will it be enough to annoy me that I didn't just fix it right to begin with.
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