Long list
Hello,
That is quite a series of questions, though the first one is by far the biggest: how to replace your stays, mast in place. As you probably know, I think this is something to avoid if you possibly can, partly in the interests of safety, partly in interest of efficiency. I do use backstay disconnection and reconnection as a project in my "Aloft" video, so you might want to take a look at that. Uppers are much harder, especially on a double-spreader mast; halyards simply can't provide sufficient support for safety. In any event, the procedure is way too big to go into here; it would be like talking you through performing an appendectomy on yourself. Is there some profound reason you can't take the mast out? I know how to do what you are planning, and have done, but I just won't any more -- no benefit remotely commensurate with the bother and risk.
As for cutting wire, I always use a bi-metal blade in a hacksaw, and smooth it out with a belt sander. On deck, I'll use a good file. Neither seem to leave particles, the way a steel wire brush wheel can. That flap wheel should do fine, too.
Non-acidic silicone is fine, though regular silicone is, too; it is very mildly acid, and even then only until it cures. But I use 4000 UV, as it adheres better to metal over time. Any sealant worth considering will create hard-to-remove residue. And a good thing, too.
Fair leads,
Brion Toss
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