Garhauer modified 40-S 4-1. It's composed of
Attaches to the underside of the boom in a track using a MetalMast vang lug MM BVS9-8 (Rig Rite).
Attaches to the mast using another MM BVS9-8. I had to cut an entrance point for the vang lug below the gooseneck.
16"x8"x7" toolbox. The following is a list of the most useful tools I carry:
| Tool | Brand | Notes |
|---|---|---|
| Fids | Selma | 4mm, 5.5mm, 7.5mm, 10mm |
| Knife | Dexter | X2S 3" Shoe Knife |
| Lineman's Pliers | ?? | 8" |
| Marker | Sharpie | Black, fine point |
| Marlingspike | Brion Toss | 6" |
| Sail Needles | ?? | Assortment |
| Sailmaker's Palm | ?? | |
| Scissors | Ascend Tools | ATI-801 Shears |
| Scratch Awl | C.S. Osborne | #4-1, 4.5" overall |
| Seizing Wire | Loos & Co. | 0.041" diameter (SLWQ041) 0.032" diameter (SLWQ032) |
| Splicing Needle | D-Splicer (Ronstan) | F20 |
| Swedish Fids | ?? | Small (6.5"), Medium (10.5") |
| Tape—Friction | ?? | ¾" wide, black |
| Tape—Vinyl Splicing | Marlow | FAB112 |
| Twine | ?? | #36 tarred nylon seine twine, 500' |
| Whipping Twine | Robline | 1mm waxed, white 0.8mm waxed, green |
| Hand Swaging Tool | Prime-Line | GD 52216 (⅛", 5⁄32", 3⁄16", ¼") |
There's lots of other supplies in my toolbox: webbing, snaps, sail slides, rigging tape, etc. The above are the most often-used tools and supplies.
Centerboard pennant — Winch handle 5/8" drive socket, 7x19 316 stainless steel wire rope, 3/16" diameter, 22' long. Wire replaced in 2020.
After double crimping at the oval (Nicopress 428-6-VX) board, the crimp diameter is supposed to be 0.340" to 0.350" to ensure a proper crimp. At the winch end, there's a stop doubly-crimped (Nicopress 872-20-M). The crimp diameter is 0.370" to 0.380".
The bronze handle is made by Merriman. It's about 6" long. The drive socket length is about 2" and its OD is 1".
I've been told that the centerboard weighs 135 lbs., but I have not verified it. However, it seems reasonable.
To lower the centerboard, use the winch handle to turn it CCW and CW to raise it. A first-order approximation is that every 10 cranks (complete turns) of the winch handle changes the angle 13°. 70 cranks lowers the centerboard down to 90°. I determined this empirically using a model—caveat emptor. On Willow, we adjust the centerboard position using only factors of 10, with us normally using no more than 40 cranks (~51°) to achieve balance.
Still (2026) trying to identify the manufacturer and model of the centerboard winch. An AI lead has it as a Merriman-Holbrook / Yacht Specialties "Model 400" or "Model 500" Series Worm-Gear Hoist.
The centerboard wire rope conduit is 0.5" in diameter.
The stern chocks were 5". One broke (2001) and I replaced it with a stainless steel 6" chock.
The standard cotter pin sizes on Willow are 3/32", 1/8" x 3/4", and 5/32" x 1". A rule of thumb for cotter pin length is 1.5 times the clevis pin diameter.
| Measure | Willow | Definition* |
|---|---|---|
| I | 45.50' | Height of fore triangle. Measured from deck sheer line abeam the mast to highest point of sail attachment. |
| J | 14.58' | Distance perpendicular from fore side of mast line to the point of intersection of the forestay with deck. |
| P | 39.45' | Luff length of mainsail measured from boom to head board in its highest position. |
| E | 16.00' | Foot length of mainsail measured from the mast to clew in its most outboard position. |
| P2 | 18.16' | Luff length of mizzen (two masted boats only) measured same as “P”. |
| E2 | 6.75' | Foot length of mizzen (two masted boats only) measured same as “E”. |
| B | 15.9' (boom) | |
| LP | Length of the Perpendicular (LP). Distance perpendicular from the luff to the clew of the largest jib or genoa. |
* Definitions from the 2003 application form of the PHRF of the Chesapeake, Inc.
Willow carries a traveling set of dock lines:
Four 40' x 5/8" 3-strand nylon
with a 12" diameter eye on one end (new 12/2006)
Four 25' x 5/8" nylon double braid (new 6/1998)
Lines kept at the dock:
Buccaneer Rope
Double Braid Dock Line, 5/8" x 25' (bow & stern, new 2018 from Defender)
Yale Nylon Brait 5/8" Single Braid White (25')
In 2000, I installed the E-Z-Jax lazy jack system. The system works OK, not great. When not in use, the lazy jacks are pulled forward and stored under the gooseneck horns.
I found that if I have the lazy jacks raised while raising the mainsail, the battens catch on the lazy jacks. When lowering the mainsail with the lazy jacks deployed, the sail sometimes gets caught on them when it comes down. However, it's better than having everything just falling on the deck.
The control lines (item 6) rub on the aft shrouds while deployed. In 2025, I replaced the lines with ¼" polyester braid with a parallel core from Blue Ox—never buy from them again. Each control line is approximately 41' long. I couldn't splice this miserable line, so I ended up seizing a bowline to the ring.
I have Selma fids in my bosun toolbox. Here are the fids and the corresponding line sizes:
| Selma Fid Details | ||||||
|---|---|---|---|---|---|---|
| Fid Size | Fid Length | Max Line Diameter | Min Line Diameter | |||
| mm | in. | mm | in. | mm | in. | mm |
| 4 | 4.57 | 116 | 5/32 | 4 | 1/8 | 3 |
| 5.5 | 5.39 | 137 | 5/16 | 8 | 3/16 | 5 |
| 7.5 | 6.81 | 173 | 7/16 | 12 | 1/4 | 6 |
| 10 | 9.06 | 230 | 9/16 | 14 | 3/8 | 10 |
| 20 | 17.72 | 450 | 1 1/4 | 32 | 15/16 | 24 |
Rule of thumb—Fid length is 21 times the rope diameter.
Merriman 1¼" wide track, 3/16" thick. The screws are hard to find. They're #18 x 1.5" stainless steel self-tapping Phillips head type AB.
On the track are two blocks on cars. The forward one is a Garhauer LLC-3UB from 2004. The aft one leading the sheet to the winch is a Garhauer LLC-2 from 2025.
Vertical pin — 15/32" D x 4 11/32" L, 9/64" cotter pin hole.
Model VXA 1D M/EH. Installed 2007.
Hairpin cotter pin for rudder attachment: wire diameter 0.062", eye diameter 5/16", length 1-5/16" (McMaster-Carr 92375A152). Pin substitutes — Ring-grip quick release pin: 1/4" diameter, usable length 3.5" (McMaster-Carr 98404A155) (need to drill cotter pin hole).
Outside pipe diameter of vertical shaft: 2.0"
Wind angle knob—3/8"-16 thread, McMaster-Carr 5532T35. The knob center needs reaming out to allow the nut to freely turn in it.
Other knobs—5/16"-18 thread, McMaster-Carr 5532T33.
I used to use 3M 101 in Sta-Lok fittings, but that's no longer available. According to an email I received from Sta-Lok, use something that's a neutral compound (i.e., no vinegar smell, no acid), like BoatLife Life Calk.
MetalMast Marine, section 8655 (8.6" x 5.5")
| Location | Dimension | Length | Type | Loos Reading |
Replaced | Other |
|---|---|---|---|---|---|---|
| Split Backstay (lowers) | 1/4" | 14' 5" from clevis pin to cotter pin hole on stud | 1x19 | 6 | 12/03 | Clevis pin 7/16" |
| Backstay (upper) | 5/16" | 35' 0" from clevis pin to clevis pin | 1x19 | 12/03 | Lower clevis pin ½" x 1 11/16". Upper clevis pin is 5/8", 1¼" usable length. | |
| Backstay join plate | 1/4" thick | |||||
| Backstay antenna from top of mast | 3' |
Sta-Lok | ||||
| Backstay angle to mast | 28° |
|||||
| Lower Shrouds | 1/4" | 1x19 | Fwd 11 Aft 11 |
4/07 |
|
|
| Upper Shrouds | 5/16" | 1x19 | 21 | 5/06 | Clevis pin
(bottom) 5/8" OD x 1 5/16" |
|
| Headstay | 5/16" | 45' 9" | 1x19 | 7/2023 | Upper and lower clevis pins are 5/8", 1¼" usable length | |
| Headstay angle | 11° | Measured from top of mast to foil — probably not very accurate. | ||||
| Inner forestay | 1/4" | ~45' | 1x19 | ½" pin, new 2003 | ||
| Mast section | 50' | Mast collar is 5' above the DWL | ||||
| Height Above Water (no antenna) | 49' | |||||
| Height Above Water (including antenna) | 53' | |||||
| Antenna Height | 3½' | |||||
| Height Above Deck | 44' | |||||
| Spreader Height Above Cabin Top | 22' 3" | |||||
| Boom Bottom Above Cabin Top | 2' 5" | |||||
| Mainsail cleat | 7" | |||||
| Rake | 0.7° | Dieter says 1.5" per 10 feet (My calculations from the sail plan shows 1.3°, i.e., 2.75" per 10') | ||||
| Upper chainplates | 1.50" x 0.39" | 15 7/8" | 316 stainless steel | Four bolts ½" x 2½", clevis
pin hole is 0.65", 0.77" from top (rebedded 2/2002) |
||
| Lower chainplates | 1.50" x 0.39" | 15 7/8" | 316 stainless steel | Four bolts ½" x 2½", clevis
pin hole is 0.50", 0.86" from top (rebedded 2/2002) |
||
| Backstay chainplates | 1.25" x 0.25" | 9 1/2" | 316 stainless steel | Three bolts 3/8" x 2", clevis pin hole is 0.50", 0.63" from top (rebedded 2/2002) | ||
| Sheave Axle | 0.50" diameter | 2" usable length | 18-8 stainless steel | Clevis pin with 5/32" cotter pin | ||
| Spreaders | 3.0" x 1.5" | 45 1/4" | ||||
| Cotter ring | 1 3/16" | Seafit 272252 | ||||
| Mast cross-section | 8⅝" x 5½" x 3/16" | MetalMast oval mast section MM-8655 | ||||
| Sail track width & depth | 1" x 3/16" | Aquabatten A009 slide |
The mast partners (collar) has an empty volume of 115 in³ and with the mast in place, it's 77 in³. That is to a depth of 2" on the collar. Also, the collar will work with Spartite with just a little bit of filing to remove recesses.
MetalMast Marine, section MM-RB450 (4.5" OD). Added internal T-track stiffener to minimize bending (2000).
| Location | Dimension |
|---|---|
| Length (measured) | 15' 9½" |
| Height | 4 ¼" |
| Width | 4 3/8" |
| Track Slot Opening | ½" |
| Track Slot Size | 7/8" |
| Track Slot Height | 3/16" |
| Track Slot Material Thickness | 3/32" |
| Groove Width - Top | 1 ¼" |
| Groove Width - Bottom | None |
| Groove Width - Sides | ¾" |
| Bottom slot opening | ½" |
| Bottom slot size | 1" |
| Bottom slot height | 3/16" |
| Bottom slot material thickness | 1/8" |
| Mainsheet attachments from end of boom | 70", 86", 102" |
| Boom vang distance from mast | 42" |
| Boom vang vertical distance | 28" |
| Boom vang angle from vertical | 56° |
Mainsheet boom attachment is to 3 stainless steel plates with tangs (MetalMast BVS9-8). The plates are 4" long and they reside in the track on the bottom of the boom. Details
MetalMast Marine. I raised the mizzen boom 1.5" so that it would clear the outboard.
| Location | Dimension | Length | Type | Replaced | Loos Reading |
|---|---|---|---|---|---|
| Forward Lower Shrouds | 3/16" | ~19' | 1x19 | 3/09 | 12 |
| Upper Shrouds | 3/16" | ~23' | 1x19 | 3/09 | 16 |
| Aft lower shrouds | 3/16" | ~12' | 1x19 | 3/09 | 20 |
| Running Backstays - wire | 3/16" | 7x19 | |||
| Running Backstays - rope | 3/8" | Double Braid | |||
| Height Above Deck | 26' | ||||
| Height above mast step without Radar Reflector | 24' 10" | ||||
| Base of Mast to top of Boom | 5' 6" | ||||
| Height from top of Boom to top of Mast | 19' 4" | ||||
| Height of spreaders above deck | 14' 2" | ||||
| Boom | 2¼" x 3¾" x 7' 8" | ||||
| Hypotenuse | 21' | ||||
| Rake | 0.7° | Dieter says 1.5" per 10 feet (My calculations from the sail plan shows 1.3°, i.e., 2.75" per 10') | |||
| Sheave Axle | 3/8" diameter | ||||
| Thru-bolts for tangs | 4½" x ½" | Stainless steel with compression tube (replaced 2/02) | |||
| Cotter ring | 7/8" | ||||
| Mast cross-section | 4⅞" x 3⅜" x ⅛" | MetalMast oval mast section MM-4833? 13" circumference | |||
| Sail track width & depth | 0.70" x 3/16" | Aquabatten A008 slide |
The mizzen mast is 21' aft of the main mast.
| Location | Dimension | Length | Type | Notes |
|---|---|---|---|---|
| Upper and aft lower chainplates | 2.00" x 0.19" | 11" | 316 stainless steel | Three bolts 3/8" x 2", clevis pin hole is 0.38", 0.44" from top (rebedded 2002) |
| Forward lower chainplates | 316 stainless steel | Three bolts 3/8" x 2", clevis pin hole is 0.38", 0.44" from top (rebedded 2002) |
| Location | Diameter | Length | Type | Color | New | Notes |
|---|---|---|---|---|---|---|
| Mainsheet | 1/2" | Double-braid | ?? | |||
| Traveller | 3/8" | 30' | Sta-Set | Blue | 2007 | x2 for both sides |
| Main halyard | 3/8" | 110' | VPC | Green fleck | 2011 | Buntline hitch at shackle |
| 3/16" wire & 7/16" rope | 50' wire & 60' rope | Wire and Sta-Set rope | 2001 | Original configuration Shackle - Ronstan RF1034 (1 9/16") |
||
| Jib halyard | 5/16" | 110' | VPC | Red fleck | 2024 | Was 3/8" & 5/32" wire-rope |
| Inner jib halyard | 5/16" | 100' | Sta-Set X | Green | 2003 | |
| Spinnaker halyard | 3/8" | 110' | VPC | Blue | 2018 | |
| Reefing lines | 5/16" | Sta-Set X | White | 2002 | 100' for all two reefing lines |
|
| Reef point lines | 5/16" | 5' | Spun Classic | White | 2025 | 3 lines for each reef point |
| Jib sheet-Port | 1/2" | 60' | Sta-Set | Red fleck | 2025 | Was 9/16" |
| Jib sheet-Starboard | 1/2" | 60' | Sta-Set | Green fleck | 2025 | Was 9/16" |
| Topping Lift | 3/8" | 110' | VPC | White | 2021 | |
| Roller furling | 3/8" | 80' | Sta-Set | White/Blue | 2021 | Decore first 26' |
| Location | Diameter | Length | Type | Color | New | Notes |
|---|---|---|---|---|---|---|
| Sheet | 7/16" | 48' | Double-braid | 2000 | ||
| Outhaul | 1/4" | 25' | Sta-Set | Blue | 2002 | Spliced on end to shackle |
| Halyard | 3/8" | 60' | VPC | Green Fleck | 2023 | |
| Topping Lift | 5/16" | 55' | VPC | Red Fleck | 2023 | |
| Reefing line | 5/16" | ?? | Sta-Set X | White | 2002 | |
| Mizzen staysail | 5/16" | 60' | VPC | Blue Fleck | 2024 | Spliced on end to shackle |
| Sail | Cloth (oz.) | Area (ft.²) | Luff | Leach | Foot | LP | Percentage | Pounds |
|---|---|---|---|---|---|---|---|---|
| Genoa #1 | 5.9 | 493.1 | 42.58' | 40.83' | 24.83' | 23.2' | 160% | |
| Genoa #2 (2006) | 8.4 | 386.0 | 42.5' | 39.0' | 18.85' | 17.25' | 120% | |
| Genoa #3 | 8.5 | 336.9 | 42.33' | 38.50' | 17.50' | 15.9' | 110% | |
| Storm Jib | 9.0 | 86.5 | 25.92' | 19.33' | 10.25' | 6.7' | 45% | |
| Main (2004) | 8.4 | 350 | 39.45' | 41.6' | 16.0' | 100% | 44 | |
| 1st Reef | 238 | 34.1' (15%) | 36' | 13.8' | 75% | |||
| 2nd Reef | 159 | 28.4' (32%) | 31' | 12.3' | 50% | |||
| Mizzen (2025) | 7.46 | 61 | 18.2' | 19.1' | 6.7' | 100% | ||
| 1st Reef | 20 | 9.3' (49%) | 10.2' | 4.3' | 33% | |||
| Mizzen Staysail | 0.75 | 159 | 24.0' (24'-28') | 18.0' (15'-19') | 19.0' (19'-21') | |||
| Cruising Spinnaker | 0.75 | 706.6 | 38.67' | 45.75' | 28.75' | SMG = 23.25' |
| Sail | Cloth (oz.) | Area (ft.²) | Luff | Leach | Foot | LP | Percentage |
|---|---|---|---|---|---|---|---|
| #1 | 5.1 | 494.4 | 45.4' | 42.8' | 23.4' | 21.8' | 150% |
| #2 | 7.2 | 416.5 | 45.0' | 41.3' | 20.2' | 18.5' | 125% |
| Working | 9.0 | 265.3 | 38.5' | 33.0' | 16.2' | 13.8' | 95% |
| Storm Jib | 9.0 | 104 | 26' | 19.5' | 11.5' | 8.0' | 55% |
| Main | 6.9 | 317 | 39.4' | 41.6' | 16.0' | ||
| Mizzen | 6.9 | 61 | 18.2' | 19.1' | 6.7' | ||
| Mizzen Staysail | 0.75 | 159 | 24.0' | 18.0' | 19.0' |
New 2022, Bacon Sails, Annapolis, MD/ Luff tape #6. This replaced our 2006 UK Sailmakers Passagemaker I Sail, Annapolis, MD.
Hood sail, R(?)54372. Eight hanks grommets plus a sail tape for a luff groove. The grommets are set back1 3/8" from the luff tape (i.e., 1 3/8" from the grommet edge closest to the luff tape). I sewed in webbing and sail hanks for raising the sail on the inner forestay. The tack should be 18 to 24" above the deck.
Hood sail. 5.9 oz. material. According to Banks, it should be 7.3 oz. They estimate (8/00) that I have a year or two left with the material, but no guaranteees about going offshore!
New mainsail, 2025 Mack Sails, Stuart, FL
Luff slides—Bainbridge A008MBK, attached via webbing
Luff slide below headboard—Bainbridge
B309 (stainless steel)
Luff batt cars—Rutgerson batten fitting 1590,
Bainbridge 3500 batten slide 22mm
Battens - Plastream Cycolac ABS
New mainsail, 2004, UK Sailmakers, Annapolis,
MD 410-268-1175
Luff - 7/8" sail slides,
Aquabatten A009
Foot - 7/8" sail slides,
Aquabatten A009
Shackles - plastic,
Aquabatten A024
Replaced leech tabling in 2022
| Batten | Width | Length |
|---|---|---|
| 1 (Top) | 38mm | 47½" |
| 2 | 38mm | 87¼" |
| 3 | 1⅜" | 43½" |
| 4 (Bottom) | 1⅜" | 40½" |
The four sail ties are 1" polyester webbing (hunter green) and are 72" long. I sewed a 9" loop into the end of each one.
New 2025, Mack Sails, Stuart, FL
Luff - 15/16" sail slides,
Aquabatten A008MBK
Foot - 7/16" sail slugs, plastic,
Aquabatten A018S
Leech line - 1/8" Dacron braided line
Battens - Plastream Cycolac ABS
Webbing holds slides to sail
| Batten | Size |
|---|---|
| 1 (Top) | 1⅜" x 16¾" |
| 2 | 1⅜" x 22½" |
| 3 | 1⅜" x 23" |
| 4 (Bottom) | 1⅜" x 19½" |
The two sail ties are 1" polyester webbing (hunter green) and are 48" long. I sewed a loop into the end of each one.
Four sheaves in mast head. They are 4.5" x 5/8" aluminum. Max 1/2" line. The sheave uses an Oilite bronze sleeve bearing, 1/2" shaft diameter, 11/16" OD and 5/8" long. These are press-fit in to the sheave.
Four sheaves in mast head. They are 2.0" x 1/2" aluminum. Max 3/8" line. The sheave uses an Oilite bronze sleeve bearing, 3/8" shaft diameter, 1/2" OD and 1/2" long. These are press-fit in to the sheave.
3/16" as primary, 1/4" for heavier duty
12 ft. x 1¼" silver track (Schaefer). The spinnaker car is a 17-84 from Schaefer. Installed 2003. The goal is to store the whisker pole on the mast to ease handling it and to free-up deck space.