I happen to think getting that Harken block to fit properly is going to turn into a major microproject. It's going to need to be lifted up, holes drilled, lead might not be fair, etc.
The wire to rope outhaul involves two swaged loops: one to the fitting that holds the clew, the other to which you tie the line's bowline; with maybe a foot of wire between the two. My setup has a little car that rides on the track right under the clew in your picture; it has a cotter pin that holds the clew to the car and another cotter pin that holds the swaged line before it goes around the wire block. Do you have that?
This is not an ideal system but it works with your existing hardware and holes. Want me to make up the little outhaul for you? I happen to have the little swaging tool and extra wire and swages lying around from my rerigging project this spring. You'd have to disassemble the wire block to feed the wire outhaul around the little sheave. The wire is quite light - it's the world's easiest swage.
Thanks Tender.
I have made a temporary fix that will should work for a while, so I have some time to consider my options.
It would certainly be easier to keep the wire cheek block especially if you were to do all the hard work, i.e. build a wire-rope outhaul. Before you offered this replacing the block was my easiest option. I even got half the wire cheek block removed and purchased the new cheek block. My plan was to use two layers of Seaboard as a spacer to lift up the block and drill and tap two machine screws.
Since my current rig should last a while lets figure out the best route forward. No rush but could you post a pic of your setup? I have a box full of parts, not sure if I have the extra parts you describe. How about a link to the swaging tool you used. By the way my sail is loose footed, not that it was designed that way but it was easier to just loose foot it when altering a used sail to fit the boat.
I am just speculating on a solution, but if I had a swage tool I could:
Run a wire through the wire block and create a loop on the end and shackle it to the clew. A loop on the other end would then catch a bowline line to the rest of the outhaul?
Here is what it looks like now, let me know what you thing is my best option?