Osteo -
Thx for yr note...y're quite right, I wld prefer built-in sheaves, but the mast is 10ft6" tall and is less than 2 1/2 inches diameter at the top. Basically, I'm afraid to cut into the damn thing any more than I already have!
This question applies to a single gaff-rigged mainsail on a small catboat, and while I agree with yr comments in theory, I worry about abrasion of the 1/4" halyards, especially since I have been unable to find any thin copper flashing as a dumb-sheave hole lining. I am considering the use of tin flashing - will that last, do y think?
Cheers, Bear.
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