DIY torsion rope clamps

[catsketcher]

I think I read on this forum that somewas looking to make their own rope clamps for a torsion rope. I have just done this. I was quoted about $550 for the end fittings which is not too bad but the torsion rope was a great deal ($50) and I got the Code 0 for helping a friend out. The furling gear was full price though.
I was going to use aluminium but I don't have a milling machine and am pretty crap with machining so I went with Tufnol. Tufnol is an old composite that seems to be made of many layers of canvas glued together. It is tough, and glues to epoxy really well. I use it around the boat a lot. I got the Tufnol pieces for $20 as scrap.
I then routedout a channel 4mm deep and 18mm wide to take two passes of 11mm torsion rope. A little grinding on the sides and some sanding at the throats to stop chafe was done as well.
I bought 12 1/4 hex bolts and nylocs to clamp the whole thing together. And when all cut out I sanded off the edges with my sander polisher.
My Code 0 is not used upwind or in big breezes. It is like a kite and only ever is hoisted to be used and comes down when not in use. It doesn't get used in big winds, but still I don't want the clamps slipping. I tried to test it with a 2 tonne jack in the shed - it didn't slip with that load but it was a bit skewiff.
I just went out and gave it a beta test on the boat. I winched the whole thing up tighter than ever and it just sat there - no noises and no issues at all. In the photos you can see I didn't cut the long torsion line but just pushed the excess back into the luff pocket. The Code 0 now rolls up much better and I am happy with the clamps. They took me about $65 and about 3 hours to make.
The money is not such a worry, I just don't like paying for things I can make in a couple of hours.
Cheers
Phil

[nuku34]

Good on ya mate! DIY is a dying art.

[Tupaia]

Excellent job and when it breaks you can make a new instead of waiting for parts. It's amazing what you can make if you put your mind to it. I have come to the conclusion that building a boat is 30% manufacturing brackets.

[Cavalier MK2]

Good job Phil, easily adjusted too.

[ilCigno]

I made my anti-torsion rope myself also. I used the Speedy Stitcher to make the eye around the heavy duty rope thimble in combination with a double layered whipping. This was by no means an easy task btw, this stuff is no 'rope'. Finished it with heat shrink tube, transparent so I can inspect the construction on possible faults.

It's in use since 2013 on my gennaker top-down furler, still in perfect shape.

[catsketcher]

Wow, that is impressive. I was going to do this but found the line was too tough for me. Well done!

[Cavalier MK2]

A drill might help, I use one when hand stitching tacks, clews etc...

[ilCigno]

I used a hammer and nail to open up the hole for the needle. Broke a few needles too. But in the end it saved me hundreds of euros so perseverance pays off.

[bccoast]

Very impressive. I was shopping online for clamps and came across this, might give it a go!