David, Graham,
the trick is simplicity. Drill a hole through the yard, put the halayard through it and secure from slipping with an eight knot. Nothing works better. All these other hooks and splices and fiddly assembling, ending in twisted yard and gap between yard and mast, forget it.
But there are details.:
- The through hole must be central through the yard, and no bigger in diameter than 8.5 mm.
- If you wish to reinforce the yard in the area of the hole, sikaflex on a strip of thin hardwood (or one of these multi-holed stainless steel dinghy shroud adapters) ON THE SIDE OF THE YARD THAT FACES THE MAST. That is the stress side.
- No need for any reinforcement if your yard material is long enough so you can drill through the overlap section where upper and lower part connect.
- To reseal the yard for buoyancy, put in a blob of PU can foam into the hole. While the foam is still sticky and expanding, push an oil covered pencil through the hole to keep that open. The oil lets you retract the pencil after the foam has set. And after retracting you have a clean canal to put the floppy halyard end through the yard in one go.
- To finish, use an old length of rope through the hole and do some see-sawing to chamfer and polish the edges of the hole.
- And yes, best use Dyneema (Spectra) for halyard material.
I drill and use holes through carbon yards since my Drascombe days. And no, I never broke any of them in sailing, however hard I tried.