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removing a broken batten
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outhaul



Joined: 27 Sep 2011
Posts: 254

PostPosted: Mon Dec 28, 2015 11:19 am    Post subject: removing a broken batten Reply with quote

The break is about a foot in from the tensioner on an Ezzy Cheetah 7.5m sail, the fourth batten down from the top. It was easy to remove the short piece but how do I now work the remaining section out? The most obvious solution would be to slice open the batten pocket but I'm hoping to avoid that if possible.
Thanks and happy holidays.
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coachg



Joined: 10 Sep 2000
Posts: 2586

PostPosted: Mon Dec 28, 2015 11:54 am    Post subject: Reply with quote

Start by emailing Ezzy for a solution to your problem. They have pretty good customer service.

Unfortunately you can't access the tip of your batten through the luff as easily as if it were the 5th or 6th batten down. You will need a large, flat, hard surface & something hard, rounded & plastic like a screwdriver handle. You need to go to the luff of the sail and use the screwdriver handle to press/squeeze the tip of your batten between the handle & the hard surface. If the broken end of your batten isn't too splintered you should be able to squeeze the batten out 1 cm at a time until you can reach in with needle nose at the leech end to grab the remaining broken end an pull the rest of the way.

A last resort would be to cut as small as a hole as possible at the broken end to be able to pull the batten out. That small hole can be easily covered with sail tape but I'd exhaust all other options before doing that.

Coachg
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joethewindsufa



Joined: 10 Oct 2010
Posts: 995
Location: Montréal

PostPosted: Mon Dec 28, 2015 12:00 pm    Post subject: Reply with quote

have had my share of busted battens - unfortunately
wrote a few posts on what worked for me
always depends how much life is left in your sail and how much you value it

http://joewindsurfer.blogspot.ca/2013/06/fixing-my-batten-what-again.html
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U2U2U2



Joined: 06 Jul 2001
Posts: 4687
Location: Shipsterns Bluff, Tasmania. Colorado

PostPosted: Mon Dec 28, 2015 12:12 pm    Post subject: Reply with quote

coachg wrote:
Start by emailing Ezzy for a solution to your problem. They have pretty good

Coachg


Do this first

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pete1111



Joined: 16 Apr 2005
Posts: 192
Location: The Dude

PostPosted: Mon Dec 28, 2015 5:40 pm    Post subject: Re: removing a broken batten Reply with quote

outhaul wrote:
The break is about a foot in from the tensioner on an Ezzy Cheetah 7.5m sail, the fourth batten down from the top. It was easy to remove the short piece but how do I now work the remaining section out? The most obvious solution would be to slice open the batten pocket but I'm hoping to avoid that if possible.
Thanks and happy holidays.


Take a 1/2 copper pipe slide it into the batten pocket and try to get the batten to go inside the pipe. Once inside the pipe you should be able to push out the batten from the mast tip.
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outhaul



Joined: 27 Sep 2011
Posts: 254

PostPosted: Mon Jan 04, 2016 5:10 pm    Post subject: Reply with quote

I was fortunate that the break was close to the end of the batten opening and was able to grab it with a forceps.
Had the break been farther in I think the only way to remove would be to slit the batten sleeve.
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bred2shred



Joined: 02 May 2000
Posts: 914
Location: Jersey Shore

PostPosted: Tue Jan 05, 2016 12:14 pm    Post subject: Reply with quote

If unable to reach the broken section of batten with a pair of needle nose pliers like you did, then typically the best recourse is to remove the batten by undoing some of the stitching on the batten pocket (not slice the pocket itself).

You can use a thread ripper or a razor blade (carefully) to remove the stiches on one side of the pocket from about 2" before to 2" after the break. Once you've removed the stitches, you should be able to access the end of the batten and pull it out through the side of the pocket (you may still need to use pliers and watch for fiberglass/carbon splinters). Note that it may take a little bit of effort to separate the pocket from the sail since it is held on with adhesive in addition to the stitches.

After the batten is removed, you can hand stitch the pocket back onto the sail using nylon sail thread (or dental floss in a pinch). Carefully sew the sail back together by aligning the pocket back in its original location and stitching back through the original needle holes. Once it's sewn back together, install a new batten, tension, and you're good to go.

sm
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outhaul



Joined: 27 Sep 2011
Posts: 254

PostPosted: Tue Jan 05, 2016 3:25 pm    Post subject: Reply with quote

@bred2shred
That sounds like a great idea, one that I'll remember for sure, but hopefully I won't ever need to do, thanks.
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Number-nine



Joined: 09 Aug 1989
Posts: 488
Location: cape cod

PostPosted: Tue Jan 05, 2016 5:08 pm    Post subject: Reply with quote

I can usually get them out by using a block of wood and tapping that with a hammer on the tip of the batten at the mast end.
Put the sail on a hard surface and drive the wood on the batten tip.

It will slide the batten out.

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outhaul



Joined: 27 Sep 2011
Posts: 254

PostPosted: Wed Jan 06, 2016 9:34 am    Post subject: Reply with quote

Number-nine wrote:
I can usually get them out by using a block of wood and tapping that with a hammer on the tip of the batten at the mast end.
Put the sail on a hard surface and drive the wood on the batten tip.

It will slide the batten out.


Maybe my technique was bad but I tried this to no avail.
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