REPLACING THE HEADSTAY

With some attention to detail and the following items, I found that replacing the wire using the existing Sta-lok fittings was well within the skill set of the average DIY sailor. The tools needed are a tape measure, hacksaw, masking tape, drill, Scotch Brite pad, wire coat hanger, a couple of wrenches, Loctite, silicone sealant, and new cones for the Sta-lok fitting.

I sourced 54 feet of 10 mm high-end Loos wire rope from Rigpro in Portsmouth, Rhode Island. With the replacement set screws for the foil, the bill came to $545.46. I was fortunate enough to have a spare Sta-lok terminal, which I installed on the new wire. By anchoring the terminals in the ground with a screwdriver, I could pull the old and new wire side by side to get an accurate measurement of length (photo 4).

I wrapped the new wire in masking tape for ease of marking and to keep the strands together as I cut them (photo 5). The old stay was a half-inch too long, so I cut the new one a half-inch shorter. Using a sharp hacksaw blade to cut the new wire saves time; any burrs need to be filed smooth.

A wire coat hanger doubled around a piece of brown Scotch Brite pad and twisted back to the drill’s chuck is an easy way to clean out the inside of the old Sta-lok fittings without damaging the threads (photo 6).

There is an insert buried in the fitting that should be removed for inspection and replaced if it is scored. I replaced the cones that slide over the wire and are captured in the Sta-lok fitting. I had to keep in mind that the lower terminal installation would need to wait until the wire was back on the mast and the foil was reinstalled.

I had to pre-fit the lower terminal (photo 7). On the wire rope, I slid the top nut onto the wire. Then, I gently unlaid the outside layer of wire strands until the new cone would go in, leaving about an eighth-inch of the core strands sticking out the bottom.

Photo 8 shows the top terminal all gooped up and ready to thread together. The fitting was gently dry-fitted first, so the cone has moved down to its home and the outer strands are bent into place. Last, I added blue Loctite to the threads and put it together (photo 9). Sta-lok says not to use too much force when tightening, so I went with a very firm feel. Sealant should (and did) ooze out the top. Wipe it clean (photo 10), and it’s all done!