Main outhaul line internal to boom

[Chris McGraw]

Welp, I've bugged Greg Henning and Don Corey enough so I'm going to use the forum.  I have replaced just about every line on #84 and have come to the main outhaul.  What I cannot figure out is how to replace the rope part of that assembly.  As you know, from the exit block on the boom it goes through a set of blocks internal to the boom and is finally tied off at the block nearest to the mast end of the boom.  Unfortunately that block is too big to maneuver while attached inside the boom and I cannot get to the knot.  Henry at Layline suggested drilling out the rivets on that block so it can be pulled out and then replacing the line that way.

Is that my only choice? 
Thanks in advance,

Chris

[Mark Allen]

Chris,
  I have replaced that line a couple of times (do not use stay set, it will do just that, twist and be unuseable) What I did was remove the block unhooking the shackle with a pair of needle nose pliers. Then I used a messenger line to remove the old line and run the new. The hard part was having the patience to connect the block back to where it attaches inside the boom. It took a while and required some patience but it can be done. It might be a lot quicker to just drill the rivets. I would suggest using a 1/4 inch line such as Swiftcord.

Mark

[Don Corey]

Hi Chris, just something to think about.  I removed the eye strap that the block is attached to and mounted the block to the backside of the gooseneck fitting.  This makes the line replacement chore a lot easier but does require a longer line.  Let me know if you want details on this as I don't recall all the parts needed.
Thought you were going to get this one by me, eh?
Don
  

[Chris McGraw]

Mark, thanks for the reply!  I'm not sure I am that patient or that coordinated to get the block back in.  Don, ha ha!  Believe me I ALWAYS want your advice; I just feel like I've asked WAY too much of you and Greg lately.  =)
OK I am going to go back out and look at this and see which route I want to go: 1. Needle nose madness, 2. Drill it out and re-rivet, or 3.  what sounds like a permanent, if complicated, solution via Don...
Thanks guys.

[Jay Harland]

My outhaul line is not in bad shape and I do not think it needs replacing, but I have looked at that internal block and scratched my head.  Nice to know there is an answer on the forum now.

Jay
Madison #73

[Dave Whyman]

I did mine last year.  If I remember correctly I bought a line that was twice as long as it needed to be so that I could drop the block out the end of the boom while feeding it.  Used the excess on the bumpers.