Ben,

This is a repair that i have done before, as it was common in the early days of RS 800's. So the process:

• Junior hacksaw the track where the split/damage ends
• Using a sharpe chistle from the side of the track and at an end of the damaged part hammer away (wear glasses as the track can be brittle and will come off in tiny bits rather that a complete piece) - only work on getting the plastic track off when hammering
• Once all of the track is off use the chistle and using it as flat against the mast as possible, scrape off the old Plexus. It will come off quite easily (this bit i always found quite satisfying)
• sand the area to key it up and to also remove any final residue of plexus.
• Cut a new piece of track to fit - tip: round off the ends of the track on both the mast and the replacement piece to reduce any chance of tareing the bolt rope.
• key up/sand the new pice of track to prepare ready for sticking
• For a clean job then mask up the mast down both edges of the track so that when the Plexus is put on it's easier to make it look like a good clean job
• generously Plexus the new track and then apply it to the mast
• place wooden lolly sticks in the join to ensure of a straight fit
• remove with a broken lolly stick any excess down the sides of the track
• and then pvc tape around the mast and track to ensure a good bond and to hold it in place - remember to remove the masking tape when cleaning up
• when dry remove all lolly sticks and tape - job done.....
• It could be a good idea to place an additional sail feeder at the top of the track to add additional protection from the main halyard/bolt rope etc.

All track and the loan of a plexus gun with Plexus can be bought/loaned from LDC. Please contact Adam Broughton (RS Retail Manager) mailto:adam@rssailing.com - adam -at- rssailing.com

Good luck and i hope this is of help.