Primary winch replacement on an Oday 34

Gimme Shelter arrived with the original winches from 1982, shiny stainless Barlow 25s. They glimmered with the reflection of the ocean as the waves rolled by.

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Unfortunately their shininess couldn’t make up for a few shortcomings.

  • Mary does not have much upper-body strength, so trimming in the 140 Genoa in anything more than the lightest wind proved impossible for her. I knew we needed bigger winches.
  • Barlow has been out of business for decades, and as I learned with my last boat, you’re always better off going with something that is still being made (or at least with a company still in business).
  • I was going to have to remove the Barlow winches anyway, whether I replaced them or not because Oday did not use any kind of backing plate when they were mounted, and the fiberglass under the starboard winch was cracking and needed to repaired.
  • The set screws that held the Barlows together were frozen, and I was most likely going to have to drill them out to get them off.

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I did quite a bit of research regarding how I could possibly get the winches off undamaged, but after two weekends of waiting on penetrating oil and trying different things, I ended up breaking the head off one set screw. At that point I just decided to dremel grooves into the bottom of the bolts on the other winch, so that I could hold each mounting screw still with a flathead screwdriver from below while I used an end wrench to unscrew the nuts.

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I ended up with one winch that I couldn’t put back together and one winch that I couldn’t take apart — at least until I finally drill out the center set screws in both and re-thread the holes.

During my struggle with the Barlows I ran across these gorgeous Lewmar 44 self-tailing winches at the local Boater’s Resale Shop, and on an impulse decided to upgrade. I mean, combined they were less than the price of one new Lewmar 44, how could I pass that up?

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I’ll admit I should have done more research before pulling the trigger on the bargain. The six allen screws in the top mean these are “spring jaw” Lewmar 44STs, which are also no longer made and no longer have parts available. I kicked myself for replacing one obsolete part with another obsolete part. However, I kept reminding myself that good winches can last 40 or 50 years, so surely they still had plenty of life in them before I’d end up hunting for some discontinued gear or pawl.

I thought they would work just like all other Lewmar winches and come apart after I removed the allen screws in the top. I was wrong. I took out the screws and nothing budged. I was delayed again as I searched for a way to disassemble Lewmar 44ST Spring Jaw Winches without them ending up in the same condition as the Barlows.

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Thankfully, the kind people at Lewmar were extremely responsive and in less than 24 hours of sending my inquiry, they sent me back a PDF of the original Lewmar 44ST Spring Jaw Self Tailing winch instructions, which I am sharing here for anyone else wondering how in the world to take these apart: https://drive.google.com/open?id=0B-eqti4pjMLTRGw5cE9FMHFoOU1OczFKcURaX3dIdGdfeFFn&authuser=0

The key is to use a rubber mallet to tap the tailing arm in a counter clockwise direction until the entire top of the winch knocks loose. Then remove the six allen screws. Then the interior ring just screws off. It’s very easy once you know how to do it.

While I was fighting with the winches I was also mixing up thickened epoxy and filling in the old winch holes as well as injecting epoxy into the cracks.

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By the way, the Barlow winches actually had six holes, but Oday only bothered to put in five screws. I’m at a loss when it comes to the decisions boat builders make.

I also made new backing boards out of 1″ oak planks. In the past I’ve used star board, but I already had the oak left over from another project, so I went with that. I also bought all new stainless hardware to make sure I had six bolts for each side that were long enough to fit through the backing boards.

I drilled the six new holes two bit sizes larger than required, then filled those holes with thickened epoxy. I then re-drilled through the epoxy with the correct bit size, so that if my bedding of 5200 under the winches ever leaked, I wouldn’t end up with any water penetration at the holes.

Unfortunately I forgot to take a photo with the six holes drilled, filled and re-drilled because at that point of the project I was either covered in epoxy or just trying to get it finished.

The port backing plate, which is located in the lazarette, went on with no issues, but I had to cut the starboard backing plate in half to make it fit through the small access hole in the ceiling of the aft berth.

I won’t go into the details of how we installed the new winches with Mary working the screwdriver from the cockpit while I held up the backing plates and worked a ratchet in a contorted position from the bowels of the ship, but eventually the winches were mounted, and our marriage has survived.

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We now have the largest self-tailing winches compatible with our line size. After using them sailing to Port Bolivar last weekend Mary’s review was, “This is a lot easier.”

Worth every penny — even if they are discontinued.

Winch replacement progress and roadblocks

Well, after sitting in the rain all weekend waiting for a chance to work on the boat, I finally made some progress on the winch replacement this morning. A star-headed screwdriver and vice grips finally gave me enough torque to break the set screw.

I wish I meant break it loose. Unfortunately I mean I broke the head off of it.

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Once the head of the bolt snapped, the Barlow 25 came apart quite easily. Mary worked the deck side of the screws while I went below with a ratchet, and we had it removed pretty quickly.

Instead of fighting the set screw in the port winch I decided to try removing the nuts from the bottom first. Magically, I was able to get all five off, so the port winch is still intact, but not serviceable. I think I’m going to have to spend a couple hours this week drilling out the set screws and re-threading the center of both winches, so we can sell them.

Meanwhile, I began filling the old winch holes in the deck and patching some of the cracks with thickened epoxy.

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I thought I’d actually finish this project today, but then I ran into the next big hurdle. Our replacement winches are vintage Lewmar 44st spring jaw winches with six allen bolts on top. I just assumed that when I removed the six allen bolts, the winch would come apart. Wrong.

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I’m stumped. I searched the internet for a diagram or service manual with no luck. I also posted on cruiserforum.com looking for help, and nobody has responded yet. Until I can figure out how to take these winches apart to drill new holes and bolt them to the deck, I’m stuck.

Anybody have an idea?

Update: Lewmar sent me the answer, and it involves a rubber mallet. I will post the instructions soon.

Winch woes

Our O’day 34 came with Barlow 25 winches. Barlow, like O’day, has been out of business for decades.

As I complete various spring-cleaning and maintenance tasks, I decided it would be a good time to service and lube the winches. However, while all previous winches I owned had some sort of snap ring holding them together, the Barlows had me stumped.

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No snap ring, no holes for a deck wrench — definitely no handy “tool free” servicing like you find in modern winches.

Also note the stress cracks in the fiberglass around the winch. O’day didn’t bother to use any sort of backing plate at all when they installed these.

To service the winch, you have to unscrew the reverse-threaded allen bolt in the center of the winch. However, being two speed winches, the winch rotates in both directions. Although I spent at least an hour trying to break the bolt loose, I was never able to budge it. I did, however, manage to strip out the head of the bolt in the port winch.

After much searching, I came across this on the Internet:

Barient/Barlow Winch Disassembly TOOL: Bar 395-Tool:
Special Tool for Assembly and Disassembly of various Barient and Barlow Winches. Tool has Winch Handle stud with a hole in the top to hold drive socket while using an allen wrench to loosen the socket screw.

Oh yeah, a tool like that would have been super helpful — too bad they don’t make them anymore.

So now I’ve got two Barlow 25 winches that, if nothing else, need to be unbolted, so that a proper backing plates can be put inside the boat.

We wandered by the Kemah Boater’s Resale shop looking for grill covers since we refuse to pay $50 for a grill cover at West Marine. (FYI, they have a million kettle-style grill covers, but no rectangular grill covers.) While we were there I spent some time looking at winches. There was only one Barlow winch in the entire store with the same type set-up as mine, and the allen bolt in the center had been replaced with a big flat-head screw. Obviously I was not the only one who had a problem with these things.

The shop actually had a set of Barlow 25 self-tailing winches for sale, but they had the much more user friendly set up with two holes in the center cap, so it could be screwed out with a deck-plate wrench. I thought about purchasing them since they were the same size and had the same bolt pattern, but then I asked myself, if I’m going to spend money to replace winches, don’t I want something that will have replacement parts if it breaks? Also, if I’m going to spend the money to change them out, don’t I want to upsize them, so Mary has an easier time trimming in the jib sheets?

Then I saw these guys sitting on the shelf for just a few dollars more.

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An executive decision was made.

No, we won’t be replacing the radar this year. No, we won’t be purchasing a dinghy this spring. Yes, we will be sailing with self tailing winches … as soon as I figure out how to get the old ones off.