Boom End Caps

[WindyT]

Hey folks!

Planning on upgrading outhaul hardware and have the screws out the end caps on the boom but these bastards are stuck!  I've been using PB blaster and a bit of heat/hammer till hearts content and haven't been able to get them off yet.  I am planning to keep grinding away but just wanted to make sure I'm not missing / hurting anything.  I've read all the prior outhaul articles etc and don't seem to be but starting to doubt myself and wanted to double check.
Thank you kindly!

WindyT

[Ben H.]

Hi WindyT,

I recently redid my boom and mast and fought with the end caps a bit too. Did all the screws come out cleanly? I had a few break off and I had to completely drill them out. Once that was done I used a punch and hammer carefully around the edge to force the cap off. (I did pretty good and only had one minor chip from hitting to close to the edge). I was also planning on replacing the worn sheaves so I hammed/pried against them as well and was able to successfully remove both caps. There was just a LOT of corrosion between the cast cap and extruded aluminum.

Best of luck.

[britinusa]

When I replaced our Boom end caps (both) I just drilled out the screws, it was not as though I was worried about the old caps.

Paul

[Ed Shankle]

Couple more comments;
- put some anti seize on the end caps and the screws when you re-install, to make it easier next time.
- if you have or are going to add a rigid boom vang, you'll should get the new goose neck end cap that doesn't rotate like the original does.

Regards,
Ed

[Craig Illman]

Drill out the screws and then tap the holes for hex head machine screws, possibly 1/4-20? Be generous with Lanocote or equivalent for next time.

Craig

[Noah]

I would use round heads not hex here. Much "prettier" and less likely to cause scratching of boom using a screwdriver, than using a socket or wrench flat to the boom. They don't need to be very tight, so no need to crank on them.

[Mark Sutherland]

I made a simple fixture/attachment for a slide hammer.  Sorry I didn't take a picture.  I bought the c30 outhaul from CD, worked great.

[WindyT]

Good copy folks!  Thank you kindly.  I'm considering dipping the entire thing in a vat of anti-seize based on this experience.

[KWKloeber]

I would use round heads not hex here. Much "prettier" and less likely to cause scratching of boom using a screwdriver, than using a socket or wrench flat to the boom. They don't need to be very tight, so no need to crank on them.

I agree on the ugliness of hex heads, but instead of Philips I would use hex DRIVE (recessed allan drive) machine screws -- they usually come in different styles -- flat, socket, and button head.  I've used all three and they work a helluvalot better than philips (which by the way is designed to slip and bung-up when stuck, rather than the head snapping off.)

k

[Mark Sutherland]

Windy, I lubed the end caps with lanocote.

[Tali]

I was able to get a broad flathead screwdriver end in between the end cap and boom.  By twisting and moving the screwdriver around to where ever I could fit it I was able to pry off the end cap of course after removing the screws.