The worn pulley is standard, I'm afraid <img src="http://www.catsailor.com/forums/images/graemlins/frown.gif" alt="" /> Happened to mine, and I think the Dutch boats too. I'm sure Vectorworks will get it sorted, but the standard one just isn't up to the job.

Hans had a good suggestion for replacing it: Take a block like this http://store.catsailor.com/tek9.asp?pg=products&specific=jmnmfnjmh0 with an eyestrap. Bend the eyestrap back on itself so that the mounting holes are back to back. Push that through the hole in the mast plate that is just below the current block and put a small bolt through the holes to retain it. This allows the block to rotate so that you can pull the halyard from different angles.

I haven't tried this yet, but will do soon. Currently, I just pull from behind the boat until the sail pops out, then I go and stand on the tramp and pull up on the rope (putting my weight on the front beam rather than the tramp).

Wouter's suggestion does work well, except that getting the rope out of the slot is an absolute pig. My fingers just aren't designed to do that. You could probably leave it out all the time, I guess. But that removes the option of throwing the rope to the back of the boat and getting The Crew to do the hoisting <img src="http://www.catsailor.com/forums/images/graemlins/wink.gif" alt="" />

Paul