Our main halyard takes a lot of abuse! Since we sail everywhere, it lives its life with the mainsail raised all the way to the sheave.
The sheave rubs on the halyard covering in one of three locations:
- Next to the shackle (full sail)
- Midway on the halyard (1st reef)
- Further on the halyard (2nd reef)
I don't spend that much time in the first or second reef, so most of the wear occurs near the shackle. Over the past 2 years, the polyester fibers have chafed and parted where they rest on the edges of the sheave. My choices are:
- Let it continue to chafe until the halyard breaks and I have the pleasure of running a new halyard inside the mast.
- Replace the whole halyard
- Cut off the worn section and re-splice the end
- Repair the cover
- Service the cover
Obviously, I am opposed to ignoring the chafe, so option 1 is lunacy to me.
Replacing the whole halyard is a pricey endeavor, being nearly 180 feet in length, a new halyard would cost around $380! That's a lot of money for a single halyard that is only 2 years old and a little worn in one spot.
Cutting off the worn section and re-splicing the shackle onto the end is a valid alternative, but over time, I will end up with a short halyard. A splice consumes a lot of rope and I like having this length of halyard so that the line can reach into the water for emergency recovery. This would work in a pinch, but not over the long term.
Repairing the cover is a valid option, this would fix the chafed cover and continue to protect the core. The problem with repairing the cover is that this area of halyard is exposed to a lot of chafe and it will wear out again in roughly the same amount of time.
The last option is to service the halyard in a very strong cordage which will repair the chafed area and protect it from further chafe in the future. When the service becomes severely chafed, I can easily remove it and re-service the area with no adverse effects to the underlying core. Best of all, serviced line is very resistant to chafe, making this repair even stronger than it originally was.
The first step is to asses the extent of the chafe. If the chafe is only affecting the cover, repairing is acceptable; if the chafe is affecting the core, consider replacing that section of line (cut off and re-splice).