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INSTRUCTIONS

Halyard sizes, cut-out dimensions and fitting procedure for the Selden AL-45, AL-70, AL-90 and C-70 sheave box (exit box) kits in the front of the mast.

DocumentSelden Sheave Box Kits Instructions
FormatPDF · 2 pages · 0.4 MB
LanguageEnglish
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InstructionsPDF · 2 p.AL-70PDF · 2 p.AL-90PDF · 2 p.C-70PDF · 1 p.
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Selden Sheave Box Kits — Instructions

Kits and Cut-Outs (not to scale)

Kit No. Kit Halyard Cut-out (length x width)
505-004-10 AL-45 Wire Ø4 mm + rope Ø10 mm, or rope only Ø12 mm 50 mm x 22 mm Ask us to source it →
505-006-10 AL-70 Wire Ø5 mm + rope Ø10 mm, or rope only Ø12 mm 72 mm x 25 mm Ask us to source it →
505-015-10 AL-90 Wire Ø7 mm + rope Ø14 mm, or rope only Ø16 mm 106 mm x 30 mm View kit →
505-067-10 C-70 Wire ø5 mm + rope ø10 mm, or rope only ø12 mm 94 mm x 28 mm Ask us to source it →

The angle between halyard and forestay must be 5-10°, but you must still be able to tension the sail.

Fitting Procedure (AL kits)

  1. Mark the drill holes A on the front of the mast.
  2. Pre-drill Ø6.5 mm, then enlarge to the hole-saw size (AL-45 Ø22 mm, AL-70 Ø25 mm, AL-90 Ø30 mm).
  3. Draw straight lines joining the hole edges on each side; check the distance equals the fitting width.
  4. Saw along the lines; file the slot edges smooth – notches can cause cracking.
  5. Put the fitting in the slot and mark the fasteners. Drill Ø5.3 mm for self-tapping screws (AL-90: Ø5.0 mm and M6 tap) or Ø6.5 mm for pop rivets.
  6. Feed the halyard (or messenger) and insert the fitting the right way up – the sheave shaft is not central.
  7. Fit the screws / pull the rivets and knock out the remaining mandrels.

C-70 Differences

  • Holes enlarged to ø28 mm (the tool list says ø25 mm hole saw, as printed). Drill Ø6.5 mm for pop rivets or screws.
  • Rivet fixing: one washer in the upper and one in the lower slot marked "-01/03". Screw fixing: the same washers plus a nut against each.
  • Insert with the arrow "UP→" pointing to the masthead and the text "-01/03" close to the front of the mast.
  • Tools: pencil, ruler, drill, jig saw, half round file, hammer, pop rivet gun or Pozidrive screwdriver.

Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.

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