I found my own answer to the question of how much load is on a halyard. I found it in the back of Riggers Apprentice. The Lewmar chart in Brion's book is helpful, I could not find it at Lewmar's website anywhere.
It looks like 2k to 3k for a monohull between 32 and 40 feet.
I ran these numbers by a sailmaker Tony Morrelli who is in the area right now. He told me he would get me another chart, but that the loads run 1st the clew, then the halyard, then the tack. He said it is pretty easy to figure the clew loads, then you use 75% of that as your halyard load.
So I can continue use 3/16" or 1/4" Dynex with a fatter tail for the part that is handled.
I just heard a rumor that a rope maker(Samson?) is selling just the cover now for folks like me who want to put our own cores in. Has anyone seen any, or know of any? Sure beats taking the core out of a perfectly good line just for the cover.
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