Tim,
Our rig is an Isomat spar on a 1984 P40.
I've done the job twice on our P40, once 19 years ago just after we bought Journey, and then again two years ago. I did all the work myself, just having a rigger do the swaging. I had the mast unstepped by the yard, disassembled and reassembled rigging all myself, then the yard restepped the mast. See the attached document for my inventory of rigging pieces and wire. The total shows about $2300, but that doesn't include the swaging (ask around but I think it was about $30/swage), any backstay insulator (these run $400-$500 each, Ouch!), and I was able to reuse the norseman fittings inside the forestay furler. It also doesn't include the cost to have the yard unstep and restep the mast (about $500 for me).
I sourced the rigging through RiggingOnly.com on the east coast. They are very helpful.
I considered doing mechanical fittings but after much research was persuaded otherwise. They are about three times as expensive, cost a lot more labor wise, and the life of the wire is still the same. On a cost basis, you have to rerig three times to break even, so that doesn't make sense. Swaged fittings are fine if you swap and replace the rigging on the timely basis (12-14 years where we live). And I've taken apart a number of norseman fittings that had scary corrosion inside, so they aren't immune either. All the professional riggers I talked to recommended swaged fittings. If you want a do-it-yourself at sea repair capability, bring a couple mechanical fittings in your spares. Also, on my mast the top end of each piece of rigging is a stemball fitting and those are only available in swaged.
Turnbuckles don't necessarily need to be replaced. I replaced mine because the chrome was all gone, so for cosmetics.
Backstay insulators, needed if you want to use an HF SSB radio. On our boat, the bottom of the backstay is not grounded so I only needed an insulator at the top, saving a good chunk of change.
If you have existing Norseman fittings that you want to reuse (like within the headstay furler), the cones for Norseman are no longer available. However, Tylaska does sell cones compatible for Norseman fittings.
So all total, I probably spent around $4000. $7000, as suggested by one of the other P40 owners, to have a rigger do everything is probably in the ballpark.
Later, I ended up replacing my Tides Marine Strong Track, which I wished I had done while the mast was down.
Chainplates: Over the years I have replaced about half of mine. Usually, they get crevice corrosion right where they go through the teak deck and you cannot see that without removing them. I would pull them all out while you have the mast down and replace as needed. I made my own chainplates, as I have access to a band saw that will cut stainless plate. Grinding and polishing is the hard part and a lot of work. I can't give you an estimate to have these made.
Also, not included here is a backstay adjuster if other than a simple turnbuckle.
Jeff Beller
S/V Journey
Ventura, CA