NP Downhaul Pulley Block: Rusting (2009 Sail)

In the topic "Broken down haul block KA Koncept 7.5", RWW provided a photo of a NP pulley block which had failed because it rusted. In his case, it looked like the axle through the sheaves had failed, see photo Rusted 1.

I looked at my owned-from-new 2009 6.7m Hellcat recently and found that it was suffering the same problem, see photo Rusting 1. I got in touch with Mark at Surfsail http://www.surfsailaustralia.com.au/showProduct/Windsurfing/Windsurfing+Accessories/443778/Ezzy+Stainless+Tack+Pulley and I gave him some dimensions of my block and asked him if the Ezzy block was similar. He replied very quickly that it was, then went to the trouble of putting the Ezzy block dimensions onto the web page, so others could compare if they were in the same predicament. He sent an Ezzy pulley very quickly.

Referring back to Rusting 1, note the round- head axle through the black webbing. I ground off the head of the axle, as shown in the photo Upper Axle and found that the axle is not round .To grind off the head, I used a 100 mm disc grinder, a new grinding wheel (there's not much room near the axle) and various long nose lock-jaw pliers to hold the mast protector pads back. Working slowly, it took about 45 minutes to do the swap. It was a bit fiddly to fit the new Ezzy axle, coming from the luff pocket side. The new pulley in place is shown the photo New 1.

RWW, thanks for the heads up on this concern. Because of a gear failure, I once had to swim 1.8kms in cold water all by myself and don't want to do it again. Have to say that this is a safety thing and readers should check their sails too.

I've changed sail brands and no rusting problems to date on the new brand.











Big thanks to Mark at SurfSail. Prompt responses to emails, thought outside the circle by adding the block dimensions and prompt despatch of the order.

Unfortunately the Ezzy pulley hasn't performed as well as I'd hoped in my NP sail.

After a few sails, I noticed that the mounting pin had bent. Got a replacement pulley and same thing happened when I rigged.
Ezzy has put it down to the pin not being supported for its full width as it is in an Ezzy sail.

Looks like it's still pretty functional.

Hi, RWW,

Could you advise the model and size of sail (Supersonic, Street Racer, etc) of the sail and the year of build please? The year can be found on the sticker attached to the foot of the sail and it starts with something like "NPGP9 XXXXX" where the 9 indicates the year.

Would also like the info about the mast, too, please. Is it the recommended NP mast or something different?

Depending on your reply, I might be able to advise more about the bent pin and so help others.

Also, that downhaul rope looks like its in failure mode and is ready for a change. Look how the weave is opening up as you scan from left to right.