How does one replace the main traveler on old style Hobie 16? Do I need to seperate the aft crossbar from one of its corner castings?

You need to drill out the last 2 or 3 rivets in the track, which will allow you to lift it up enough to remove and replace the traveller car. Be careful only to drill out the head and not enlarge the hole. Then replace with countersunk rivets. The post below gives some hints on what to do to re-rivet the track back successfully.

http://www.catsailor.com/forums/sho...ew=collapsed&sb=5&o=&fpart=1