Please select your home edition
Edition
Cyclops Marine 2023 November - LEADERBOARD

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.

Barton Marine Pipe GlandsV-DRY-XVetus-Maxwell 2021 v2 FOOTER

Related Articles

Admiral's Cup 2025 | Welcome from Cowes
Bow Caddy Media provide an introduction and interview with Shane Guanaria from Zen Ahead of the first race, Crosbie Lorimer provides an introduction and interviews Shane Guanaria from Zen
Posted on 18 Jul
Aussies hunt 'Ashes on Water' win
The BONDS Flying Roos are looking to bounce back with a vengeance in Portsmouth Fresh off a bruising weekend in New York, the BONDS Flying Roos are looking to bounce back with a vengeance as they take on long time rivals Great Britain in their home waters at the Emirates Great Britain Sail Grand Prix, held in Portsmouth.
Posted on 18 Jul
4 Ultim rocketships to contest Rolex Fastnet Race
The giant 32m long by 23m wide flying trimarans are taking part in the 100th anniversary edition While the 50ft flying catamarans competing at SailGP Portsmouth this weekend will be impressive, charging out of the opposite western end of the Solent will be giant 32m long by 23m wide flying Ultim trimarans taking part in the 100th anniversary edition.
Posted on 18 Jul
SailGP comes to Portsmouth!
We speak to the sailors ahead of the weekend The Emirates Great Britain Sail Grand Prix | Portsmouth takes place this weekend, with the 12 teams competing in F50 catamarans close to the waterfront, where a massive grandstand has been built for the spectators.
Posted on 18 Jul
SailGP: No practice racing at Portsmouth
The Practice Race was a fizzer, however the future of the SailGP fleet development was revealed. The scheduled Practice Day failed to fire at SailGP Portsmouth, after the forecast, admittedly light, breeze failed to male an appearance. The self propelled start marks were making a much better speed than the F50s.
Posted on 18 Jul
McIntyre Mini Globe Race Leg 3 Preview
The race to South Africa starts from Vuda Marina Fiji on 26th July In a world-first sailing challenge, 15 solo sailors from eight countries are navigating identical 5.8-meter (19-foot) self-built plywood yachts around the globe— The fleet has enjoyed a five week stopover in Fiji at the end of Leg 2.
Posted on 18 Jul
Third time Finn World No.1 for Alessandro Marega
Maintaining the top spot in the Finn World Ranking List Italy's Alessandro Marega maintains the top spot in the Finn World Ranking List for the third consecutive release. He remains World No. 1 with an 80-point lead over France's Laurent Hay.
Posted on 18 Jul
World Sailing Nations Cup to make grand return
After a seven-year hiatus, World Sailing has officially opened the bid process for host cities After a seven-year hiatus, the World Sailing Nations Cup, the ultimate event to crown the world's top match-racing nations, is making its much-anticipated return.
Posted on 18 Jul
J/99s the in Noakes Sydney Gold Coast Yacht Race
There will be a race within a race taking place in the 63 yacht fleet When the fleet of 63 yachts set off in the 2025 Noakes Sydney Gold Coast (NSGCYR) on 26 July, there will be a race within a race taking place.
Posted on 18 Jul
2025 WASZP Pre-Games in Weymouth Day 2
A classic British summer's day as sailors launched beneath a blanket of grey cloud and drizzle The second day of the WASZP Pre-Games served up a classic British summer's day as sailors launched beneath a blanket of grey cloud and with a hug of fresh drizzle.
Posted on 18 Jul