Please select your home edition
Edition
Lloyd Stevenson - AC INEOS 1456x180px TOP

Traveller repair- Turning a $2000+ replacement into a $360 repair

by Vincent Bossley on 11 Jul 2011
Traveller repair SW
Vincent Bossley here describes how a little perseverance and ingenuity, together with some pleasant time in the sun, turned a $2000 replacement into a $360 repair: The mainsheet traveller on a friends 43ft (13mtre) sailboat was showing signs of wear. The traveller was installed on the yacht when it was built and so now was twenty two years young.

The traveller track itself was still in good order but the bearings inside the car were beginning to disintergrate. When you consider the constant pressure on these bearings when under sail over the years and many many thousands of sea miles, it is not surprising that at some point they will require some attention.

The symptoms of course were that the traveller was wanting less to slide and becoming more difficult to shift and generally getting more stiff - which in turn becomes more of a handicap when sailing.

The starting point was to take down the headlining in the aft stateroom and head/shower cubicle underneath the traveller. Let me tell you from the outset that this was the most time consuming and awkward part of the job. Always working in a confined space, the temperature rises along with the fiddly nature of the work.

This part accomplished we moved topsides to remove the sheet lines from the traveller block and sheave of the traveller and secure the boom off. this meant that the car could slide freely along the traveller rail. All eighteen heavy duty screws were removed from the traveller rail so we could then lift the rail away from its position. The end caps were prised off so that we could then slide off the car. As you can see from the image, the bearings (four each side, totalling eight) were in pretty bad shape with constant wear and corrosion over time having taken their toll.


In preparation ahead of time new bearings had been located which were five millimetres underwidth of the old ones. The reason here was that the difference in diameter was to be made up by pressing on a composite material called Delrin (Semi-Crystalline Engineering Thermoplastic). This was done by a local engineering company for a paltry sum of $20.00 including a spare set! The bearings themselves came to $246.00.


These were easily placed into position on their pins and the car slid back onto its rail. The track was then firmly remounted in its position on the bridgedeck. Two Ronstan deck organisers were purchased at $50.00 each and positioned at each end of the track and using the existing camcleats. The lines were fed back through and the car tested for smoothness of operation. Needless to say, it worked beautifully and with the composite 'Delrin' material the car ran very smoothly.


Apart from time, the all up cost of the job of bearings, Delrin press-ons and sheaves was $366.00. The replacement cost of a new traveller system from the manufacturer was $2000.00+. So, we felt we were well ahead and even if it were to wear again say in five years time, there is a second set of press-ons available.


The boat has been out sailing - and racing - several times since the refurbished car and traveller was refitted and to date is performing very well indeed. Composite materials are used so widely these days, especially so in sailing and yacht building that there is no reason to suspect that the Delrin coated bearings will not give many years of sterling service.

You can read more about sailboat equipment servicing, maintenance and refurbishing in Vince's ebook 'Voyage of the Little Ship Tere Moana' downloadable, and then there's the very handy publication, '101 Dollar-Saving Tips for Sailors', both available by http://www.sailboat2adventure.com/!clicking_here.

Mackay Boats 728x90 BOTTOMNorth Sails Loft 57 PodcastBarton Marine Pipe Glands

Related Articles

British Dragon South West Championship
A spectacular warm-up for the 2025 Edinburgh Cup Torquay delivered a spectacular warm-up for the 2025 Edinburgh Cup, as 13 Dragon teams took to the waters of Tor Bay for the South West Championship, a two-day regatta packed with shifting breezes, tactical gambles, and top-class racing.
Posted today at 8:59 am
Foiling Sport Congress gathers global players
To shape the Future of Foiling Last week, Malcesine hosted the first-ever Foiling Sport Congress — a by-invitation event organised to foster an in-depth discussion on the current state and future developments of foiling across all disciplines.
Posted today at 5:59 am
Gran Canaria Gloria Windsurf World Cup Day 3
The best female wave sailors in the world showcase their skills on the global stage After the men had taken centre stage for the opening two days of the 2025 Gran Canaria Gloria Windsurf World Cup, today was the day for the best female wave sailors in the world to showcase their skills on the global stage.
Posted today at 4:11 am
Transpac Onboard Episode 4
Anything Can Happen at Sea All Transpac 2025 competitors are now at sea and actively racing to Hawaii. We take a look at the Pasha Live Race Tracker and talk about the significant wind hole confronting a contingent of competitors.
Posted today at 3:06 am
Stops & re-starts in first two legs of AEGEAN 600
A tough first night and early morning spent fighting zephyrs getting through the Cyclades After a beautiful breezy start yesterday, but a tough first night and early morning spent fighting zephyrs getting through the Cyclades, at the end of today's daylight the AEGEAN 600 fleet is back on the move.
Posted on 7 Jul
Marblehead to Halifax Race Update
The front-runners are pushing hard toward the finish After nearly 24 hours at sea, the front-runners of the Marblehead to Halifax Ocean Race are pushing hard toward the finish. Temptation/Oakcliff leads the fleet in both elapsed and corrected time, with Boudicca – Gill Race Team close behind.
Posted on 7 Jul
British Classic Week Day 1
Northerly winds gusting 22 knots make for a brisk start Day one at British Classic Week in Cowes saw fast-paced racing around the cans sponsored by Spirit Yachts for over 50 classic and modern classic yachts.
Posted on 7 Jul
International Moth Worlds Opening Ceremony
137 sailors from 25 nations have gathered, featuring some of the biggest names in sailing After weeks of preparation and an intense lead-up, the 2025 Moth World Championship is ready to get under way. Official racing begins tomorrow, 8 July, on the waters of Lake Garda, with the event hosted by Fraglia Vela Malcesine.
Posted on 7 Jul
iQFOiL Worlds a Aarhus day 2
No racing, but spirits stay high in Aarhus Day 2 of the iQFOiL World Championship in Aarhus tested the patience of sailors, coaches, and the Race Committee alike, as the wind refused to settle across the bay.
Posted on 7 Jul
Foiling Frenzy at Fraglia Vela Malcesine
The Moth Worlds at Lake Garda are something else! The Moth Worlds at Lake Garda are something else! Regardless of where sailors are in their careers, or the reputation they have, everyone wants to be there and have a tilt at the title.
Posted on 7 Jul