When I had my Express 27, I had good luck using Yale Crystaline for the halyards ... 1/4 inch for the forward two and 5/16 inch for the main. Left the cover on, made it about five feet longer than absolutely necessary, used luggage tag splices for the shackles. Every year we'd end for end them, cut off about a foot of the shackle end, and put a new luggage tag on the other end. Halyards were trusty and safe for at least four years.

It also helps to cover up the exposed core at the shackles while stored. Just takes a little velcro 'boot'.

:: I also am interested in going back to non tapered jib
:: and main halyard- Whats the minimum size folks are
:: using?