Aluminum spreader bars

Moderator: GreenLake

Aluminum spreader bars

Postby boatblogger » Sun Oct 02, 2011 2:30 am

I recently bought a DS-1 that needs a few things fixed up. The rudder and tiller are badly constructed and I am building new. What is the length of the stock tiller?I have a blank cut out but I want to make sure it's not too long at 48 inches.

I have installed a tabernacle and now feel more comfortable about the raising process. Unfortunately I appear to be missing the spreaders. I see on this forum a lot of people who have dispensed with the upper spreaders. I wish to replace the lower spreaders and see that the units available commercially are 1/2" x 21". I can get the same stock for half the cost at Home Depot. Is there anything wrong with making my own by simply drilling the appropriate holes in one end and sawing a slot in the other to receive the stay?

I would appreciate any input from you experienced DS-1 hands. I may have more questions in the future. I would love to hear form anyone on the Olympic Peninsula of Washington. Also, please check out my blog at http://www.seawardadventures.com.
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Spreaders

Postby rnlivingston » Sun Oct 02, 2011 9:12 am

D&R Marine here in Massachusetts is your best source for spreaders. I made a set for a friend of mine from aluminum stock from Home Depot, but they only lasted one season.
Roger Livingston
DS 6872
Mariner 4096
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Postby TimD » Sun Oct 02, 2011 11:16 am

Launching earlier this year, I broke one of my spreaders. I ordered a new set from Cape Cod Ship building. Unfortunately, it was the new design. Aeronuatical and much longer.
Trying to keep a somewhat original appearance, I acquired some stock aluminum tubing, cut it to length & drilled the holes and was able to salvage the screw in pieces from the originals. The tubing came from Grainger for $10 in a 6ft length.
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Postby GreenLake » Mon Oct 03, 2011 1:24 am

@boatblogger: Aluminum alloys are not all created equally. Especially when sailing in saltwater some grades might be more susceptible to corrosion than others. Unlike stainless steel, it's near impossible to find out what grade the alloy is that you can purchase locally.

As Roger writes, D&R is your "goto" place for much of the stuff where sourcing it locally is difficult and Rudy there is intimately knowledgeable about the boat.

@rnlivingston: Some DS's have factory installed spreader brackets that aren't even original DS design, but something the builder substituted. That's the case for my boat. After special ordering a pair from D&R so I didn't have to replace the brackets, I found that they lasted less than one season.

Upon reflection, I'm now convinced that there's a design defect that makes them susceptible to breaking at the bracket. I judge my emergency repair as more durable than the original design....that says something.

@TimD: I'd say, beefier is better. I don't understand the "much longer" part. How long were the ones that you got from CCS?
~ green ~ lake ~ ~
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Postby Alan » Mon Oct 03, 2011 12:13 pm

The spreader bars that came with my 1980 DSII, as well as the heavy duty ones I bought from D&R, are 21-5/16 inches long. The aerodynamic bars I bought from Dwyer Mast (to go with a Dwyer DM-2 mast) are 24-3/16 inches long.
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Postby jeadstx » Mon Oct 03, 2011 4:03 pm

When I bought my DS2 it had the light weight standard spreaders on it. They didn't last long. I bought a pair of the heavy weight ones from D&R about 4-1/2 years ago and they still in good shape. The heavy ones have squared ends where they attach to the brackets. Image

John
1976 Day Sailer II, #8075 - Completed the 2011, 2012, and 2013 Texas 200
1952 Beetle Boat Swan Catboat
Early Rhodes 19
1973 Mariner 2+2, #2607 - Completed 2014, 2015 and 2016 Texas 200
1969 Day Sailer I, #3229
Fleet 135; Canyon Lake, Texas
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Postby TimD » Mon Oct 03, 2011 4:49 pm

Greenlake- The original spreaders I have are about 8" or so, the ones sent from CCSB were 21" 5/16 & came with a new style bracket.
The spreaders I'm referring to are the upper spreaders, & CCSB apparently does not make the spreaders for the pin style bracket anymore.

Can someone enlighten me on lower spreaders?- ie. placement, general purpose etc..

Thanks,

Tim
Last edited by TimD on Mon Oct 03, 2011 5:04 pm, edited 1 time in total.
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Postby jeadstx » Mon Oct 03, 2011 4:59 pm

TimD,

I think the standard spreader length is about 21-1/4" long. If your original spreaders are 8" long, they are too short. Sounds like someone replaced your spreaders with jumper spreaders which are shorter.

John
1976 Day Sailer II, #8075 - Completed the 2011, 2012, and 2013 Texas 200
1952 Beetle Boat Swan Catboat
Early Rhodes 19
1973 Mariner 2+2, #2607 - Completed 2014, 2015 and 2016 Texas 200
1969 Day Sailer I, #3229
Fleet 135; Canyon Lake, Texas
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Postby TimD » Mon Oct 03, 2011 5:10 pm

The spreaders that I have are the jumper spreaders as seen on the DS1 manual pg2
Last edited by TimD on Mon Oct 03, 2011 5:27 pm, edited 1 time in total.
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Postby TimD » Mon Oct 03, 2011 5:24 pm

Excuse, my ignorance. So where do the other spreaders go?
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Postby jeadstx » Mon Oct 03, 2011 5:39 pm

Jumper spreaders are on the upper part of the mast. Your main spreaders should be the same place as my DS2 pictured (with my original spreaders). Image

Here is a page from an old O'Day Brochure of the DS1 showing the main spreaders and the jumpers. Image Hopefully it will help.

John
1976 Day Sailer II, #8075 - Completed the 2011, 2012, and 2013 Texas 200
1952 Beetle Boat Swan Catboat
Early Rhodes 19
1973 Mariner 2+2, #2607 - Completed 2014, 2015 and 2016 Texas 200
1969 Day Sailer I, #3229
Fleet 135; Canyon Lake, Texas
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Postby GreenLake » Mon Oct 03, 2011 5:41 pm

The jumper struts (and the diamond stays) can be safely removed - according to many posts here by apparently knowledgeable and experienced people.

The spreaders attach several feet below where the side stays (shrouds) attache to the mast. Their purpose is to
  1. give a better angle for the upper part of the stays so that the leverage in pulling the mast sideways is better
  2. push the mast forward by being swept back

You should not sail without them, because otherwise your mast is not properly supported. Your mast would have brackets for them, or if those are missing, the holes where they used to go. And, yes, they are about 21" long. You could vary that length slightly if you were to adjust the length of the wires as well, but in addition to any restrictions in the class rules, you'd want to not go overboard with changing these dimensions.
~ green ~ lake ~ ~
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Postby TimD » Mon Oct 03, 2011 5:55 pm

Thanks guys
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Spreaders

Postby jpclowes » Tue Oct 04, 2011 8:09 am

I replaced mine, and made them myself, but I used stainless steel tubing instead of aluminum. The stainless works much better and I haven't had to replace any since then. Before that I went through about 3 in two years.
J .P. Clowes
Eastern Great Lakes Regional V.P.
DSI 14083
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Postby K.C. Walker » Tue Oct 04, 2011 9:25 am

My boat has half-inch square aluminum bar stock for spreaders. Judging by the oxidation on them, I'd say the original owner made these replacements a long time ago.

Chris, welcome aboard! I enjoyed checking out your blog. I think you're really going to enjoy having your DaySailer. It is the perfect frugal sailor’s yacht. Also, as you point out in your blog, trailering really gives you an amazing variety of sailing.
KC Walker, DS 1 #7002
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