Hello Everyone,
I bought my first Hobie 16 and my first sailboat on April 27th. It's a 1981 Summer Nationals (Banana Hulls). It's in great shape, no soft spots, no damage, and a good trailer. However, some of the pulleys seem to have disintegrated, especially the jib sheet car and as a result, it was shredding my jib sheet.
I decided to put my CAD skills to work and I designed a replacement pulley on SolidWorks and 3D printed it. I used a Lulzbot Mini on a 50% infill with ABS. I planned to use PolyCarbonate but ABS surprised me with its rigidity. After printing the two half pulleys, I got the old one out with a drill bit, this was definitely not the best way of doing this but it worked. I used gorilla glue and rubber bands to help secure the pulley and allow it to cure.
Here are two videos of it done curing and it rigged up
Finally, to conclude I will attach a link to my Thingiverse page where you can download the files to print this at home. Additionally, I'm not sure if this is allowed but if there is interest I will gladly produce these and send up to 4 of them to you for 5 dollars. If you are interested let me know!
Thanks for reading, I put a lot of effort into this and I hope at least one person can benefit from this.
P.S. Sorry for the giant images, at least they are high quality!