Replacing the Standing Rigging on our Catalina 34 Sailboat

Replacing the Standing Rigging.

Our biggest job on Eximius in the ten plus years we have owned her.

Eximius is insured by Geico - BoatUS and the policy is due to be renewed in May of 2026, they sent us a letter advising that we needed to have a Survey done before the renewal.  Our plan is to have the boat out for it's semi annual bottom refinish during a haul out in January 2026, so it sounds like a good time to get the Survey done, if not during the haul out then at least shortly after.

The Standing Rigging was inspected two years ago but has not been changed out during our ownership, and most rigging companies seem to suggest that standing rigging should be replaced around the 10th year. Our rigging still looks good but more on that later.

Having made the decision to replace the rigging, my first quote was from a local rigging company, they are 'the' company in South Florida, we had them do the inspection two years ago and we have purchased several running rigging products in the last 10 years, including replacement blocks for our halyards and reefing lines just a few months ago. Their quote was over $15,000. That did include un-stepping the mast, replacing the standing rigging, re-stepping the mast and tuning the rigging. The only additional cost would be the storage of the mast at the marina while the work was being done.

My next option to consider was Synthetic rigging which I really like. I have replaced all of the lifelines on Eximius with Dyneema, that was in 2017 - Eight years ago and they are still holding up. That was a full DIY job and was definitely not an expensive option.  The Quote from the Synthetic rigging company was for a DIY job but they would supply all of the rigging materials. That was just over $6,000 and quite honestly, I was sorely tempted to go that route. Among other things, we could carry a complete set of the standing rigging as spares and barely hit the total weight of the Stainless rigging.

Then I looked up the cost of a DIY job using replacement rigging from Catalina Direct - Wow!

The entire project was going to cost less than $4,000 including tax and shipping.

So, I spoke with Kevin at Catalina Direct to confirm I had put all of the bits needed into my cart at https://www.catalinadirect.com Then completed the order. The initial shipping for the order was $12, but I knew that was not the final number, it turned out to be $175. That brought the cost to $3,986.87. 

I placed the order on 12/10/2025 and it arrived this morning, Friday Dec 19th. WooHoo!

Time to plan the work.

Step 1: Check the inventory.

The order came in two boxes. I was impressed by the UPS driver whom did not seem to break a sweat bringing them to my door. Awkward to carry and quite heavy.

The contents were very well packaged and padded with both scrunched paper and bio-degradable chips. 

Each set of shrouds was packed inside of Large Ziplock bags and the smaller components inside an additional smaller zip lock bag.

Some of the shrouds were held together with plastic tie wraps but some were not. I was concerned about taking them out of the bags and not being able to get them back in. So I opened the bags and put my own tie wraps on the wires to stop them springing out of control when I pulled them out of the bags.

I took photos of each bag before unwrapping them in order to check that each had the correct kit of pieces - Turnbuckles, T-Bolts, Compression Fittings, etc.

Everything was fine except the Forestay package. The kit should have included a  compression fitting for the top of the stay, but instead, there was a small T-bolt fitting. Thank goodness it was not a wrong shroud.

I called Kevin at Catalina Direct, he asked me to take pictures of the kit and send them. I already had the pics so I sent them while he was on the phone. 

The good news is that the Forestay is the last item on the plan for the Standing rigging job. So a few days waiting for the shipment of the correct fitting is no big deal at all.  It does prove that it's always worth checking the received items as soon as possible when an order arrives.

Ok, moving on.

The instructions for making the Compression fittings are pretty clear - Here's a link to the instructions.

Basically, I have to remove the shroud/stay, lay it on the dock alongside the new wire and fittings. Cut the new wire to fit and make up the compression fitting.

Generally, the plan is to replace one shroud/stay at a time. 

• Secure the mast with an extra line from the mast head to the deck 
• Ease the Turnbuckle at the foot of the shroud/stay 
• Climb the mast and release the shroud then lower it to the deck, descend back to the deck 
• Disconnect the lower end of the shroud to the chainplate.
• Lay the shroud/stay on the dock and mark the new one to the correct length
• Cut the new shroud/stay and make up the compression fitting
• Ascend the mast and hoist the new shroud/stay and replace it
• Back on deck tighten the shroud.

I have a Spinlock Rig Sense tensioner, so I'll take note the tension before removing the old and after installing the new.

To climb the mast I'll be using our 'Mast Mate' mast climbing ladder which should speed things a lot compared to having to use ascenders to climb the mast.

It might work out that the lower shrouds can be replaced in pairs but I don't think I'll risk changing out both mast head shrouds at the same time. So the job will involve as many  as 7 trips up the mast not including the forestay, so perhaps eight all together.

That's the plan. I hope Peggy will be on hand to man the safety winch line and to take pictures and videos.

We're planning on a trip to Lake Boca for the New Year's Eve cruise, so more important is to complete the Diesel Fuel Tank install.  Waiting on some hose clamps, should arrive today  ( 12/20/2025), but I have some I could use temporarily if the new ones are late. So I should be able to complete the fuel tank on Monday 12/22. Just need to get the Diesel cans full and finish the job.

Part two of this post should be the start of the re-rigging. Tuesday??

See you on the water.