Duracell project: Manufacture of an end cap for the mainsail halyard


Matt continues the restoration of his Duracell 60-footer, with the manufacture of carbon hinges and the fitting of a hardened bowsprit to store the mainsail halyard.

Optimized hinges

After building his first hinges for the yacht's bathroom cupboards, Matt had to build a new set for the cockpit lockers. Knowing that many more would follow during Duracell's refit, he had a friend make a CNC-cut mold. The insert tubes are now made of plastic, and smart tooling with a unique wedge to be placed in different positions on the table saw, allows him to make the comb cuts. Matt is very pleased with the result, with light, well-made hinges.

Cockpit equipment

Matt then cuts out the backs of the cockpit seats. Using a jig, he makes oblong openings to create crew compartments in the coaming. These will be used to store winch cranks, as well as personal equipment.

A halyard swivel

On a 60-footer, the mainsail halyard is dozens of meters long, and needs to be stored while sailing. For comfortable cruising, it's a good idea not to have it in the middle of the cockpit. Matt therefore proposes to make a dedicated compartment below deck, drained in the manner of an anchor locker. He makes an opening in the coaming and deck with an oblong tube, which he laminates himself around two plastic tubes. Sheltered by the roof cap, it shouldn't take on too much water. The halyard, neatly stowed away, should be a thing of the past!

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