Cutting New Halyard Exits

[Brian Duff]

I cant see much additional strength comming from a thin stainless or aluminum plate fastened with one to four screws. I prefer to have no halyard exit plats and just a well rounded and nice looking slot. No corrosion issue either.

Cut the slots by using a holesaw or stepped bit to 1/2" or 3/4" or whatever width suits your halyards, by about 2.5" hole center , again depending on halyard size. Then take your jigsaw, and use a sharp woodcutting or aluminum cutting blade, cut on the slowest speed your jigsaw has, and be careful to cut straigt, and fair into the radius of the holes you drilled on each end. The neater job you do cutting, the less filing later. Be sure to produce smooth sides and round the inside and outside edges well. Use some sandpaper on your finger to get the upper inside edge really well.

Fun Fun !