[Public-list] Fw: Shackles for New Mast Top

[Brian and Elaine Timmins]

Stephen,
  I've gotten personally involved in modifying the shackles to fit the new Mast Top for Christos and Alfredo (close, local friends), since I work with and have access to appropriate tools. Chris suggested that I post my modifications for others benefit.
  As all involved know, the suggested shackles don't fit between the outer plates on the new fitting. I modified the new shackles using a 4 1/2" mini-grinder, a cutting disk (very thin) and a grinding disk.
  First, I used the cutting disk to slice a thin sliver off one side of the shackle (about 1/8" between the disk's thickness and the sliver). This alone allows the shackle to fit between the plates.
  Next problem was fitting the pin. The slot in the shackle is not deep enough to fit the pin. Using the 1/4" thick grinding disk's edge, I started lengthening the slot. It didn't take too much to get the pin to fit, but the angle that the shackle was at was no where near correct for either of the stays. I started this with a 4 1/2" disk which was almost at it's maximum reach. I switched to a 6" X 1/4" grinding disk and continued on the slot. After several grind and check cycles, i found that by lengthening the slot all the way to the top of the Schafer Logo, the shackle fit and pivotted enough for either the forestay or backstay to have a straight lead. Of course, it has been a few years since I have been up close and personal with an Alberg 30 Mast top with tight shrouds, so I might have gone a little too far. Considering the importance of a fair lead (especially on the forestay), I think not.
  Disclaimer..... I am not a design engineer and accept no responsibility for any work or design changes done by "others". I am also notirying my freinds that I did the work for that I accept no responsibility for the changes made to the parts (shackles). If they or others use the parts I modified or the methods, measurements proposed above, it is at their own risk.
Regards,
Brian    ex#497
----- Original Message ----- 
From: Christos Katehis 
To: Brian and Elaine Timmins 
Sent: Tuesday, April 19, 2005 8:47 PM
Subject: Re: Shackles


I was thinking about that too (the slot), I wasn't sure if that had to be modified as well. Perhaps you should post your process on the list so the others can do the same. All in all it's a booboo on the designers side.



 If it passes Brians test, it's fine with me



Thanks,

Chris


  -------------- Original message from Brian and Elaine Timmins <timmins at optonline.net>: -------------- 


  No, not with the right tools. Besides cutting down one side to make it fit into the mast top plates, I had to cut the slot longer to allow them to take reasonable angles to match the shrouds. They should be fine now. I want you to see (take) them well before you need them, just in case.
  BT
    ----- Original Message ----- 
    From: Christos Katehis 
    To: Brian and Elaine Timmins 
    Sent: Tuesday, April 19, 2005 4:06 PM
    Subject: Re: Shackles


    Thanks Brian;



    I will probably need them in two weeks, so in your trunk is a good idea. Was it tought work?



    Chris




     

      -------------- Original message from Brian and Elaine Timmins <timmins at optonline.net>: -------------- 


      Shackles and mast top are ready. I'll keep them in my trunk.
      BT