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Forespar Leisure Furl OFFSHORE IN-BOOM FURLING SYSTEM, Installation Manual

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Forespar Leisure Furl OFFSHORE IN-BOOM FURLING SYSTEM Installation Manual Download Page 10

10

The aluminum luff foil system is 12” shorter than the base extrusion system.  The
“cut length” of foil is the piece which goes at the top, and the cut end must be at
the very top of the foil system

.  This placement ensures that the sail will never be in

contact with a cut end of foil.  Slide the cut length of foil to the top of the base extrusion
and push a stainless steel retainer clip (See Diagram 3b) into the bottom. Continue
sliding 6’ lengths of foil onto the base extrusion, placing a stainless steel retainer clip into
the bottom of each length.  These retainer clips help hold the foil lengths in place during
installation and establish a .020 gap between each length of foil.  

Ensure that the

bottom end of the aluminum luff foil is 12” above the end of the base extrusion.
This is an important dimension to allow sufficient of the flex feeder fastener and
the base extrusion

.

The .020 gaps in the base extrusion joints and luff foil joints allow for modest mast bend
without crushing the ends of the extrusions.

INSTALLING THE 30” POLYMER FLEX FEEDER

Any burrs or sharp edges on the ends of the foils will cause luff tape friction, wear and
failure.  This is why the only “field-cut” length of foil is at the very top of the luff  foil assembly
where the sail never reaches.  Inspect all luff foil ends during installation and smooth as
necessary using fine grit emery cloth.  

When the luff foils are fully installed, the bottom

must be 12” above the bottom of the base extrusion. 

 Now the 30” polymer flex feeder

is slid onto the base extrusion and secured using the two 10-24 X 1/2” fillister head ma-
chine screws.  Drill using 9/64” bit.  Carefully use the flex feeder as a drill guide to locate
the fastener locations on the base extrusion.  DO NOT drill the base extrusion through the
flex feeder.  This action could result in the holes in the flex feeder being elongated.  It is the
shear strength of these screws that holds the flex feeder in place.  Apply LocTite and tighten
them making sure their heads are below the inside surface of the flex feeder.

Summary of Contents for Leisure Furl OFFSHORE IN-BOOM FURLING SYSTEM

Page 1: ...1 OFFSHORE IN BOOM FURLING SYSTEM Installation Manual September 26 2014 ...

Page 2: ...ents 12 Installation drive components 13 Installation Boom and Mandrel 14 Installation Boom and Mandrel and Deck Layout 15 Deck layout 16 Sail fitting instructions 17 Mainsheet and vang bail fitting 18 Installation checklist 19 Global agent listing 20 IMPORTANT TOPPING LIFT INFORMATION TO INSTALLERS OWNERS 21 Your Notes 22 IMPORTANT INFORMATION TO INSTALLERS OWNERS FORESPAR PRODUCTS CORP 22322 GIL...

Page 3: ...the Leisure furl system is entirely at your own risk We accept no liability for personal injury or property damage resulting from faulty installation Nor do we accept warranty claims resulting from faulty installation Do not install a Leisure furl system except on the boat for which it was specifically designed and manufactured The Vang Lug Sheet Bails All vang lugs and sheet bails are shipped loo...

Page 4: ...5 Outer bearing 23 Seating compound 6 Universal 24 Owners manual 7 Inner bearing 25 Cardboard template 8 Support bracket straight edge 9 Drive shaft 10 Spool cover 11 Rope guide 12 Furling line 13 Mandrel lock 14 Sail Cover All bracketed 15 Luff lube Items not shown 16 Universal sock but are 17 Sail lashing in parts kit 18 Set up kit 19 Spool packers 1 2 3 7 6 4 8 5 10 9 13 11 12 ...

Page 5: ...c grinder 4 Masking tape Tapping drill sizes 9 64 3 16 1 4 5 16 Drills sizes 3 16 1 4 5 16 3 8 Intermediate taps 3 16 1 4 5 16 3 8 Tap wrench Anti corrosion compound LanocoteTM or similar compound LocTite Center punch Mixing stick Sand paper 180 or 220 grit Cutting knife long blade Winch handle Tape measure Round file Pop rivet gun to suit 3 16 rivets Boson s chair ...

Page 6: ...1 4 1 7 8 4 2 32 18 18 6 L 1 1 4 1 7 8 3 3 4 1 7 8 32 18 18 6 M 1 1 4 1 7 8 3 3 4 1 7 8 32 18 18 6 H 1 1 4 1 7 8 4 2 32 18 19 6 1 1 4 1 7 8 4 1 8 2 1 16 32 18 20 7 1 1 4 5 16 2 1 8 4 1 8 2 1 16 34 18 25 8 1 1 4 5 16 2 1 8 4 1 8 2 1 16 34 18 25 8 O S 1 1 4 5 16 2 1 8 4 1 2 Carbon 2 1 4 34 18 Fiber Diagram 1 18 For start of base extrusion see chart below Datum is center of drive shaft Bottom of P is...

Page 7: ...isting vessel there are several points to consider As can be seen from Diagram 2 if the gooseneck is positioned in the same place as previously in the case of a retrofit the bottom of P will rise up around 6 to 8 This will mean a small amount of sail area will be lost but the area can usually be trimmed off the top of the sail so the loss will be minimal A second consideration is the boom height i...

Page 8: ...ore mounting slugs into the mast luff slot raise to a convenient waist level and place a piece of masking tape across slot to hold up the slugs 5 Hold the cut length of base extrusion that has the fairing block attached against the back of the mast and thread a 20 flat head machine screw FHMS through the base and into the slug 6 While pushing the track base upward as you work engage a slug for eac...

Page 9: ...il portions are aluminum extrusions and a polymer flex feeder After mounting the aluminum base extrusion with a 020 gap between lengths slide on the foil The foil pieces are held in place during installation by a stainless steel retaining clip which is pushed into the bottom of each length of foil Diagram 3b The bolt rope foil sections must have smooth and fair edges The necessary space of 020 bet...

Page 10: ...s and luff foil joints allow for modest mast bend without crushing the ends of the extrusions INSTALLING THE 30 POLYMER FLEX FEEDER Any burrs or sharp edges on the ends of the foils will cause luff tape friction wear and failure This is why the only field cut length of foil is at the very top of the luff foil assembly where the sail never reaches Inspect all luff foil ends during installation and ...

Page 11: ...ing the track forward to install the second termination block A piece of light line tied around the mast and luff track may be handy here to hold the track in the forward flexed position Each installation is a little different and the desired amount of flex has to be determined by hoisting and furling the sail The furling operation should be done several times with eyes on the luff of the sail Ens...

Page 12: ...e opposite end of the mast fore or aft to the wiring tube Through this first hole wedge the wiring tube over to one side as you drill the opposing drive shaft hole With a round file debur the edges of both holes Dry fit the Spool and Inner Bearing castings to ensure that the castings fit the profile neatly It is important that the center of the Spool casting touches against the mast before either ...

Page 13: ...n the clamping assembly This compresses the castings against the mast profile The seating compound will spill out from the edges If there are areas that obviously require more compound use the excess that has spilled out to fill but if the weather is hot be quick as you may not have a lot of time At this stage tape both the top and bottom of the castings right around the mast to secure while the c...

Page 14: ... mainsheet tangs are tight in position as they may have become loose in transit Fit the mandrel to the drive shaft Slide the universal coupling onto the drive shaft which will have to be cut to length until it touches the Inner Bearing If when fitted the shaft protrudes through the back face of the universal drive coupling the shaft will need to be cut shorter by the length that it protrudes See D...

Page 15: ...must not be a drive fit Debur the edges of the hole then refit the spool to the mast Align the drive pin holes and fit the drive pin Use a grease or similar when fitting the drive pin so as it assist with future removal Fit the leather cover and O ring over the inner bearing casting flange Slide the universal onto the drive shaft Roll the O ring into the groove retaining the drive pin and pull the...

Page 16: ...ating switch and control lines in the cockpit in a position to allow this Use of the existing rope clutches may determine the position for operation The operating switch should be positioned in such a way to allow the operator the freedom to use both hands for man aging the system With an electric winch probably the best position in cockpit floor for foot operation Use another winch to snub main h...

Page 17: ...he spool face plate roll the sail onto the port side of the mandrel We recommend two persons assist by pulling either the luff or leach so as to ensure the bolt rope remains in the area between the boom edge and the mast whilst the sail is being furled 6 In some special cases hoisting the sail from the deck may be preferred as the spool and boom height from the deck may inhibit manual fitting In t...

Page 18: ... hole then slide the bail out of the way and drill the second hole through the top of the track 4 The drill used must be sharp so as not to leave a burr extending into the lower cavity of the boom Use a deburring tool if necessary to remove any burrs which could possibly damage the sail cover 5 When all the holes have been drilled for the bail use Loc Tite on the dog and the threads of each set sc...

Page 19: ...7 Ensure the track joins are aligned and deburred 8 Ensure the flexible feeder and limit line is set up correctly See Diagram 4 9 Ensure the luff track top cap is in place and will not allow halyard chafe 10 Ensure there are no objects or sharp edges between the feeder and gooseneck for the sail to catch on 11 Ensure the furling line is lead aft avoiding friction where possible and the rope guide ...

Page 20: ... Emailplemaout aol com Leisure furl International PO Box 22800 Otahuhu Auckland New Zealand www leisurefurl co nz GERMANY Reckmann GmbH SiemensstraBe 37 39 D 25462 Rellingen Ph 49 4101 38490 Fax 49 4101 384950 HOLLAND Romar b v De Hagen 17 8325 DB Vollenhove Holland Ph 31 527 241 735 Fax 31 527 244 181 Email romarbv worldonline nl Proctor Holland b v Middenhavendam 1 4511 AX Breskens Ph 31 117 381...

Page 21: ...lt by compressing the aft end of the MANDREL into the AFT END STRUCTURE The higher the boom is raised the closer the aft end of the MANDREL comes to the AFT END STRUCTURE Monitor the MANDREL END GAP during the entire process of topping the boom above the 87o operational angle Always prevent the mandrel from compressing into the AFT END STRUCTURE IMPORTANT NOTICE TO OWNERS AND INSTALLERS COMMON OCC...

Page 22: ... Connect the shock cord to the top fixed slide and tie to the middle moving slide 7 Set the Leisure FurlTM boom to the correct 87o operation angle and mark the mast at the location of the moving slide 8 Line up the moving slide with the reference mark on the mast and you re ready to reef or furl Thanks to John Baxter and Chuck Omalley of Doyle Sailmakers along with the guys at Atlantic Spars Riggi...

Page 23: ...ases the load in the sail gets the sail off the shrouds and spreaders and in creases the efficiency of the universal Ensure that the end float between the universal inner face and the inner bearing casting is no more than 1 16 If a topping lift only is being used to support the boom tie a knot in the topping lift line aft of the rope clutch or cleat to ensure that if someone accidentally releases ...

Page 24: ...locks be installed properly see Dia 4 page 11 An additional issue results from reefing with a batten on the flex feeder Cyclical batten thrust forces will cause the flex feeder to fracture ALWAYS REFF THE SAIL SO A BATTEN IS ON THE FURLING MANDREL Abatten in this location provides outhaul tension to the foot of the reefed sail The leaf spring component dramatically softens the hard point transitio...

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