Great!!! Thanks to all for the advice.... I'll forget the wire pig and go with an extra five feet of line.

Bill

I'd go w/ Harold's T900 idea, forget the wire, but cut the halyard about 5' longer than needed. 5' won't create too much of an additional rats nest, and this will give you at least 5 chances to shorten the halyard when the end gets chewed up for any reason. If you have a halyard length piece of messenger handy and end-for-end the halyard you can get still extra use from it.

Rope can be very expensive, especially since the J/24 class rule requires halyard diameter to be so overkill. If you call a rigger they will do everything they can to sell you a gucci new shackle and a splice. They will also recommend a minimum length halyard. This adds a significant expense to the halyard, and it guarantees that the halyard will always chafe in the exactly same places. Since it only has to break in one spot you will end up replacing it after only a season or two.

I always order my halyards a few feet longer than required and then I tie small tight knots to the shackles. That way I can cut the knot off and retie it to the shackle whenever the halyard starts to look a little worn. Many times we have been on our way to the starting line when we have discovered the abrasion. If there isn’t a splice it is a simple thing to fix. It is also a good idea to stitch a cover to the jib halyard where it goes through the cam cleats. Make sure the extra cover is long enough to accommodate cutting the shackles off a few times.

Finally, rope technology moves as fast or faster than sailcloth technology. It seems that every time I buy a new halyard there is something new. I always try to buy the highest quality halyard I can find, and then I try to make it last as long as possible.

Bill,
Try T900, and provided your main halyard sheave is smooth (no scoring, sharp edges or burrs...very few are)you can try this solution: Put a figure eight knot in the end of the halyard, fold over the top 3 inches below the knot and push the resulting loop through the headboard of your mainsail, lastly put the figure eight over the top of the headboard through the loop and tighten by pulling up (this will enable you to get max hoist, minimum weight aloft, and you won't even have to buy a halyard shackle! (very Gucci!) (just make sure that your headboard holes don't have sharp edges). The wire pig tail is the other good way to go.
Good Luck, and best regards!
___(\(\(\_(\__/)_______/)_/)____(\___/)___/)___/)__________

Need to install a new main halyard. Any recomendations? I've heard Aracom-T or Stayset-X. What about wear at the sheave? Should I spend an extra $50 to splice in 2' of wire?