Fish It wrote:
Maybe it's a design flaw... gazillions of wheels, hubs and other applications are held in place with a washer and a cotter pin. Why would this application be any different, other than this is simply the way Hobie designed it?
You could be right. No doubt, Cotter pins are excellent for certain applications, such as the ones you mentioned. While there is nothing that would prevent their use with the outhaul clevis pins, IMO Cotter pins tend to work best with a non-rotating hole where the pin can be manipulated without squirming around.
Among the advantages ring clips have over cotters in this application are 1) they are removable without tools (very handy when you're at sea), they are reusable, they don't snag and they can be removed and replaced much faster than Cotters. IMO, they are 100% as reliable in this application.
The original Mirage Drives made good use of Cotter pins for years as can be seen here:

So it's doubtful that Hobie is ignorant of the uses and benefits of Cotter pins. Rather, it's likely that they have come up with better devices for these applications.
If you feel that cotter pins are the best way to go for the clew outhauls, give them a try and let us know how they work out.
