Thirty years ago, when I had a Stiletto 27, I switched from a wire/rope halyard to a 2:1 high modulous line halyard. Part of the reason was a wonky shoulder, the same one that is flaring up now. Both the Stiletto and my current F-24 MK1 have bolt rope-in-slot luffs, which can be high friction for the size of the sail. It's a new sail and moves as smoothly as any I have seen, so that is not the problem.
I'm not sure how much clearance there is between the fully hoisted sail and the masthead. Some, because it tension well with a winch. But I need to hoist and probably look from down the dock with a spotting scope.
These images give me an idea of the other clearances.
- There seems to be enough fore-aft offset between the pulley pin and the pin the topping lift is secured to for the dead end of the 2:1 halyard. My blue ladder is hanging from the main halyard (red), so it looks to be a good 1.5 inches forward of the pin. If I knot the halyard to the pin, the knot will not contact the sheave attached to the head of the sail. But I will need a low-profile sheave stack. I might just lash a large LFR to the head grommet, pretty slippery with Dyneema, low profile, light, and no chafe points.
- There are some sharp spots cause by a shackle hitting the masthead I should do something with. But they have not chafed my current halyard, so probably not a big problem.
I'm thinking 8 mm NER Viper with a stripped (about 6 mm) last 25-30 feet is the proper rope. The current halyard is10 mm polyester DB.