Lewmar Sheet Track Cars

At build in 1997 Kiriwina was fitted with four of these genoa cars. Two for the Yankee and two for the staysail.

They are still in excellent condition and have not had any problems.
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In April 2006 I wanted to add another car to each genoa track at the aft end to ensure a clear sheet run to the winches. Otherwise on certain points of sail the sheets led around a midships stanchion.
I purchased two slightly different Lewmar genoa cars (the originals not being available).

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The later cars have not performed well. By April 2007 they were rusting heavily.
Lewmar sent two replacements.
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They did not do well in warmer climates.
In August 2009 one sheave broke.
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Then in October 2011 a second sheave broke.
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Replacement sheaves are not available. A new car costs £120 in the UK.
To replace both £240 plus shipping.

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This part of the car seems quite good.
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The sheave and bracket seem to be the problem.
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I decided to try having some new sheaves made.

First stop was to purchase a 50cm rod of PTFE (Teflon).
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The old sheaves had to be cut out.
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A little engineering shop tucked away in the back of Tigre did an excellent job with the machining. Two new sheaves fitted to the brackets and four spares.
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Lemar's method of securing the sheaves is a bit agricultural. We used a stainless steel allen bolts with two washers and a locking nut.
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Old and new.
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Costs. PTFE rod Arg$110 (Arg$20 per sheave and still enough left for another four sheaves). Two sets of bolts and washers Arg$40. Machining Arg$40 per sheave.

Not bad. Arg$80 (£11.70) per car to replace the sheave. We will see how well they work later this year.