A spreader cap should allow the stay to move through it when the tension changes right?

i got a problem with my spreader caps. When I was removing the rigging the stainless bolts that hold the caps on were seized inside the alloy spreader and only 1 of 4 bolts came free. The rest sheared off. So I had to drill them out and re-tap for the next size up. Which went fine until the last one where it went all pear shaped. Literally.

And to bundle that issue up, the current design pretty much clamps the diamond stay to the spreader and prohibits it from moving when the tension is adjusted, particularly once it oxidises between the stainless and alloy.

so now I am wondering if it's worth febricating new bolt-on spreader caps out of stainless, with a nylon insert or something. Or are there off the shelf units I could buy? I did try searching the net but came up empty.

I don't really want to pay a guy to weld on fresh material for a new hole cause I still think the current setup has flaws that should be fixed while the mast is down.

In most instances the end should be fixed to the stay, in your case it appears to be designed to clamp. You obviously have only a single spreader rig, if you had a multi spreader rig where D2 terminates at spreader tip 1 (and D3 at spreader tip 2 etc) it is essential that the spreader tip is fixed by V1 to take loading of D2 etc up the mast.
A non fixed spreader end will not slide along the stay during tensioning ( other than perhaps whilst the stays have absolutely no tension.)

If you coat everything with tef-gel when reassembled you will not have an issue next time.
In regard to gripping the stay, don't nip up tension on the spreader cap until you have rig tension, then manipulate the spreader to the correct position and nip up the spreader cap. If you are adjusting the reg tension after that, it should only make minimal difference to the spreader. if it does loosen the cap and tap the spreader into the correct position.

Ok well that's all good advice. The cheapest solution ended up being making some custom ones from scratch. They don't clamp on but bolt through the solid block of alloy that's on the tips of the spreader. I could add additional perpendicular bolts of clamping is necessary?

i rounded the tips and deepened the groove slightly so the stay sticks out from the alloy a little less.

Oh oh and I painted the mast

Hi Felixdecat, having similar problem with my "new "28 which at great expense has had mast removed and new stays being made up. Rigger plans to simply push out old wires and not try to move seized bolts and threat through new wire.
Another issue that has arisen fortunately with mast removal was broken pin at base of mast which allowed mast rotation. Not pretty. Having new base made up but will loose rotation and some performance but a have a more reliable rig. Meanwhile in mastless land before venturing north.

Hi Beachedbro

I think i saw your girl for sale a little while ago. I collect any details about beach marines I see on the net cause its not always easy to find.

Yours is the one with the extended transom steps right? I was curious to know if your rudders still fold up?

I had no issue with the mast base/pin. Shame to lose the rotation though. It's a solid plus for cat performance. Is it a cost issue?

I've got the new rig but clearing a few other projects off my list before I re-rig for spring.