My balls fell out

Wet Spreaders

Super Anarchist
2,445
260
SF Bay
So I have to service the traveler car. Questions:

1. Is this a "Harken Mid Range"? I think so. I looks like it needs 1/4" balls, right?

2. It came off the track when the balls fell out. Is it possible to replace one end cap, put it back on the track, fill it with new balls one at a time and then put the other end cap back on? Or do I need to remove the track and slide it on carefully using the "loader" tool?

And while I'm at it, I found one of the pulleys has cracked. I Googled around, but I can't seem to find a part number for the stainless mount, double pulley arrangement. Ideas?

IMG_0527.jpg

 

Varan

Super Anarchist
6,521
1,703
Mine did that once, back in the days of tight leather pants. Good thing I had a guitar in hand. Seriously, get a ball loader. I have some if you did one.

 

Zonker

Super Anarchist
8,871
4,781
Canada
1. Yes, looks like a mid range car. We had a big boat car and I think the car extended under the pulley more. Also it had a forged not stamped shackle. You can buy Torlon balls cheaper than Harken sells them I think.

2. Sort of:  (a) turn upside down and replace balls using the blue plastic loader (b) remove end cap (c) slide on holding loader in place carefully.(e) replace loader

3. https://shop.toadmarinesupply.com/ships_store/?p=details&ident=174477&mfc=Harken&sku=1799&prod_name=Big+Boat+Hi-Load+Double+Control+Blocks+(set%2F2)&sectionid=5093   part #1799 but I'd guess it's out of production. I'd try eBay.

 

FinnFish

Super Anarchist
3,648
293
So I have to service the traveler car. Questions:

1. Is this a "Harken Mid Range"? I think so. I looks like it needs 1/4" balls, right?

2. It came off the track when the balls fell out. Is it possible to replace one end cap, put it back on the track, fill it with new balls one at a time and then put the other end cap back on? Or do I need to remove the track and slide it on carefully using the "loader" tool?

And while I'm at it, I found one of the pulleys has cracked. I Googled around, but I can't seem to find a part number for the stainless mount, double pulley arrangement. Ideas?

View attachment 370359
Email Harken they're as help as all fuck and often have what you need on the shelf.

 

Dead air

Member
234
19
If you can’t lay your hands on a loader at short notice then shaving foam will hold the balls long enough to slide it back on the track and still washes out easily. 
 

pay attention to the number of balls, it is possible to put too many in!

 
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Wet Spreaders

Super Anarchist
2,445
260
SF Bay
Did the balls fall out spontaneously before the car came off the track?

In that case simply replacing them will not solve your problem
Not spontaeous - the plastic end cap tha traps the balls broke. At a minimum I need new end caps and I'm pretty sure I lost some of the balls, so my plan is to buy new end caps and new balls and reassemble. 

Harken's website is very slow right now and I can't get their technical data to check whether what I have is a mid range or a big boat version. I'm hoping someone knows by sight, then I can order the end caps from Harken and the balls from McMaster. I can 3D print a small piece of track to use to assemble everything, but I can't get at the ends of the track because the fiberglass is in the way. I'm hoping someone has a technique for mounting it on the track ball-less, and fitting the balls later. I'm guessing that it's not easy.

 

ctutmark

Super Anarchist
1,739
279
PNW
The end caps need to be slid onto one end of the track unless you are feeling really lucky about flexing them enough to snap them over the track.  For some sizes Harken makes aluminum replacement caps versus the original plastic ones.

It is possible to load bearings with everything on the track but it is at best a challenge. If you can remove at least one side of your traveler sheaves it will make things easier. As others have mentioned it is possible to put too many bearings into a car, typically 1 extra per side will "fit". If you have too many it will have lots of additional friction.  Shaving cream and then flushing it with hot water can be helpful.  

 

shaggy

Super Anarchist
9,709
963
Co
Sigh, the delema..  Buy a $400 windward sheeting assembly + $100 track..  Decision sucks, but think about it.   Besides the tiller, what does a driver use the most??   Wrestled with the old non captive bearing cars for years...  Too many headaches to list here.  Lost balls, trav getting stuck needing a kick, balls all over the cockpit floor durring a cross..  etc, etc, etc. ..  (and yes they are still rolling around in the bilge) It's a pain in the ass to keep an old trav going.  Replace it and don't think about it for another 20 yrs........IMHO....

 

shaggy

Super Anarchist
9,709
963
Co
Sigh, the delema..  Buy a $400 windward sheeting assembly + $100 track..  Decision sucks, but think about it.   Besides the tiller, what does a driver use the most??   Wrestled with the old non captive bearing cars for years...  Too many headaches to list here.  Lost balls, trav getting stuck needing a kick, balls all over the cockpit floor durring a cross..  etc, etc, etc. ..  (and yes they are still rolling around in the bilge) It's a pain in the ass to keep an old trav going.  Replace it and don't think about it for another 20 yrs........IMHO....
Edit to add, ebay and 30 bucks got me a new car......  Windward sheeting assembly and new track were a bit more $$$$$ I must admit...

 

zenmasterfred

Super Anarchist
1,532
534
Lopez Island
Just spent a whole day getting balls back in my outhaul car, not a Harken and from France so getting a loader was out of the question. Used Harken Torlon balls to replace the lost ones although I think I got more in the car than came out of it, runs smoothly now.  Part of replacing sheaves in the boom thanks to Zephyrwerks for 1 day turnaround on replacement sheaves, Ed it top drawer. Took several years off my life I think.  A loader is the best way to do it. FPITA!

 
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