Genoa car - replacement sheave

[MINESAPINT2]

Just noticed my sheave has been seized for a while and has a big groove worn in it. Simple/cheap solution would be to replace sheave - wonder if replacements are available??. U sheave plastic/nylon +/- 40mm diameter 30mm wide 8mm pin.

Alternatively replace whole car but boat is 30 years old and I guess I will not be able to find a match. Will try to upload a photo later. Just tried but file too large.

Thanks

Mike

 

[ash2020]

Mike. If you can't find anything, I 3D print that sort of thing in Nylon. I'd be happy to do one for a nominal charge.

 

[Boathook]

Sheaves are available but you might have to compromise on the pin diameter, either bigger or smaller. Smaller is easier to sort out with a drill bit. Big problem I have found is removing the 'pin' as riveted in place. Normally I replace with a bolt with a nyloc nut. If I'm lucky the bolt will have a plain shaft for the sheave to run on.

 

[Arcady]

FWIW I used one of the harder fillers (“Chemical Metal” as I recall) to effect a temporary fix on a similarly worn sheave, once I had freed it up. The sheave was still working fine several years later when I sold the boat.

 

[thinwater]

Just noticed my sheave has been seized for a while and has a big groove worn in it. Simple/cheap solution would be to replace sheave - wonder if replacements are available??. U sheave plastic/nylon +/- 40mm diameter 30mm wide 8mm pin.

Alternatively replace whole car but boat is 30 years old and I guess I will not be able to find a match. Will try to upload a photo later. Just tried but file too large.

Thanks

Mike

a. Any photo editor should have a resample/resize function to reduce resolution.
b. You could have one turned by any machine shop. In fact, this can be done on a drill press with simple adaptation. Cut a rough blank with a hole saw, turn the outside, and then re-drill. Or you can easily re-turn one that is a little larger, if you can find such.

 

[DinghyMan]

I can make you one if you get stuck, or just send me the car and I'll do the remove old, make new, & refit for you

 

[wonkywinch]

Latest Sailing Fair Isle has scary clip of genoa car coming loose

 

[MikeCC]

Get a suitable diameter bar of acetal or delrin. Should be able to find a local machine shop or hobbyist who will turn it to match existing. Make two while you're at it and do the other side.

 

[chris-s]

I replaced one on our last boat made from some nylon spacers off eBay.

 

[William_H]

As said the problem is getting the axle out as it is probably rivetted in. Drill in to each end of rivetted part to destroy it. Sheaves are usually easy to find replacements for. For the axle I used 6mm ss tubing in mine with a bolt and nut through it so cheeks are tightened against the tubing which is long enough to provide clearance each side of sheave. Or as said just fit a bolt with nylock nut. ol'will

 

[MINESAPINT2]

Update.......

Thanks for all the advice and offers of help.

I discovered Osculati supply a perfect replacement for my sheave. 40mm diameter/33.5mm wide/8.3mm bore. Only issue was obtaining one. They are available from Italy or Latvia but very scarce in UK. A chandlery in London had them listed on their web site but when I contacted them they would have to order one in from Italy. ABC Powermarine had them listed on their ebay site as "out of stock". However when I phoned them to enquire whether they will be getting any stock soon they found one in their stock room - I will get it in a couple of days - £9.

I then spent an hour in my shed removing the damaged sheave and pin. Hacksawed down each side of the sheave and removed it along with the central section of the pin, being careful not to damage the aluminium car. Drilled out the 2 remaining bits of the pin at each side and cleaned it all up. I have some 8mm round 316 stainless solid bar to use as a rivet so just waiting for the sheave.

Bit of luck will be sailing again next week.

Mike

 

[Never Grumble]

There is a guy on eBay who sells them (if its Lewmar)

 

[William_H]

Update.......

Thanks for all the advice and offers of help.

I discovered Osculati supply a perfect replacement for my sheave. 40mm diameter/33.5mm wide/8.3mm bore. Only issue was obtaining one. They are available from Italy or Latvia but very scarce in UK. A chandlery in London had them listed on their web site but when I contacted them they would have to order one in from Italy. ABC Powermarine had them listed on their ebay site as "out of stock". However when I phoned them to enquire whether they will be getting any stock soon they found one in their stock room - I will get it in a couple of days - £9.

I then spent an hour in my shed removing the damaged sheave and pin. Hacksawed down each side of the sheave and removed it along with the central section of the pin, being careful not to damage the aluminium car. Drilled out the 2 remaining bits of the pin at each side and cleaned it all up. I have some 8mm round 316 stainless solid bar to use as a rivet so just waiting for the sheave.

Bit of luck will be sailing again next week.

Mike

I think you will find the old axle had a reduced diameter end where it goes through the cheek so that the cheeks are kept apart by the axle. The turned down part goes through the hole and is riveted over. You could try without this step in the shaft (axle) but may find the cheeks want to squeeze together and foul the sheave. If you can turn down the ends of the shaft a little you may like to try holes and split pins to hold it in or even drill a hole in the end of the shaft and tap a screw in each end. As I said I used ss tubing for shaft and a smaller bolt with nylock nut right through. ol'will

 

[DinghyMan]

As mentioned about about the axle: be very careful when removing it as hammering on it to punch it out can easily break the cheeks