Harken Mark III Unit 1 Furler; Lower Toggle

[Headway]

I am currently re-rigging a Malo 36 with a Harken Mark III Unit 1 headsail furler. The cotter pin in the lower toggle appears to be pressed in and can't be disassembled. Harken have quoted £1,000 for a new lower toggle !!! Any experiences of this would be appreciated.

 

[zoidberg]

Buying American leaves you wide open to extortionate demands.
I'm certain a local engineering workshop could sort that out for you for less than 1/10 of the quoted Harken price.

 

[Headway]

Indeed my initial thoughts. It seems a relatively simple assembly to reproduce. Just trying to work out how to disassemble; the cotter pin doesn’t a split pin or grub screw to locate it.

 

[Chiara’s slave]

Mine isn’t a Harken, but it has the same design. The cotter pin is pressed in. There is no way to remove it. If you want to take the foils off the forestay, you will have to cut the top swage off. The replacement fitting will obviously shorten the forestay wire. Plus of course, putting the foil back together will be a nightmare for various reasons, the nylon guides, the joint locking screws, they are all designed to be fitted, used, then thrown away when they get old.