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I am replacing the halyard block at the top of the mast on my 26S.

The previous (and still current) block is bolted through the lip on the slot, affording very little working room. I've drilled out the old screws to get the block off, and then cut some of the bolt shank but it is tough to get the hack saw very close to the mast. Now I'm stuck with bits of shank that are too long to push through the hole and remove. Next step will be to take a grinder to them and remove enough that I can push them through the holes.

My question is whether anyone has a clever idea for getting new bolts in. The gap at the narrow point of the mast slot is too small to get a box-end wrench in to hold a nut while tightening the bolt. I'm leery of just using a screw (no nut on the end).

I'd welcome your ideas.

--john

A picture would help, but I would say you might have to alter a tool to work.

Is it something like this?


If so, maybe a crow’s foot?





Or take your cutoff wheel to one of your old wrenches. I might cut the side out of a box wrench if I couldn’t get a whole box wrench on it. I’ve had to cut up and bend wrenches to work on various situations a lot over the years.

If it’s actually in the slot, I’d make a wrench out of flat strap and bend it to fit in the slot.

The top picture is good, but where your bolts are inside the mast structure, mine are in the slot where the sail slugs go.

Build my own tool? I see this as an exciting opportunity.

Thanks.

--john

Interim wrote: ↑Tue Apr 08, 2025 8:03 am The top picture is good, but where your bolts are inside the mast structure, mine are in the slot where the sail slugs go.

That is what I would call poor design. I usually invent a few new phrases when confronted with something like that (very few of which are anatomically feasible).

Good luck! Let us know how you get it done.

Is the bolt threaded into the mast, or just welded with corrosion? Could you put vice grips on the nub and back it out of the nut - if you could get a wrench on it?

I'm assuming that the slug slot where the bolt (nut?) is located is above the pulley, so you could maybe just be able to cut the slot open enough to access the it?

Grind off the bolt heads to remove.
Drill new holes inboard enough to install the way the pict shows?
I wonder if the "inside the track" holds the nuts in place?

A rotary cutoff wheel tool maybe?
Can you share a picture of what you’re dealing with?

Mine was a pita to change. But I made my own out of titanium so hopefully I won’t have to do it again.

Ix

Follow up...

I drilled out the bolts on the old block to get it off, and put a new block on by hanging it off the two braces that extend from the top of the mast to hold the top of the backstay. I drilled a hole through the braces, and put a 1/2" bolt through the shackle on the block.

I hope this doesn't put too much pressure on those braces. Time will tell.

--interim

I am late to this thread. I was wondering if something like this would have worked.



Too late for this, but, hopefully will help another.

Nice work Ixneigh!
Titanium!
(Youknowthatwhenthealienarcheologistsinthelongdistantfuturedigupyerboattheyregonnanodwithapprovalatyerhandiwork! )

Best Regards,
Over Easy

OverEasy wrote: ↑Thu May 08, 2025 2:23 pm Nice work Ixneigh!
Titanium!

Agreed. That's some impressive fabrication.