GENINS05 Page 5
28/08/2014
Assembly Instructions: Z SPARS Genoa Furling System
ALL SYSTEMS ARE SUPPLIED WITH A NEW FORESTAY. TYPICALLY
THIS WILL HAVE A RIGGING SCREW AT THE BASE.
Establish the length of the forestay before determining the foil length. This can be
done by calculation or by trial installation of the forestay on the mast etc.. Do not
swage the lower terminal on the Forestay until assembly of the Furling System is
complete.
NB
In all cases the Forestay Rigging Screw MUST be compatible with the Furling
Drum and must have the special double hole toggle fitted to the lower end. (see
drawing FS-1).
Assembly of the Luff Foil
The length of the foil required can be determined by reference to our technical sheet. The
foil length must be trimmed from the top as the bottom end has a machined sail entry slot
and it is essential that its position relative to the lower end of the foil be maintained.
If the luff foil (6) is not supplied in one complete section, connect the aluminium sections
that make up the foil using the Foil Connector Sleeves (17) and socket set screws m6x8
(16). Use Loctite 638 on the threads. These screws are best inserted from
inside
the foil,
not from the outside.
Forestay top terminals vary from boat to boat. If the Foil End Cap (21) will not fit over the
forestay top terminal, feed the Foil End Cap onto the forestay from the bottom of the
forestay at this stage.
Feed the pvc sleeving onto the wire from the end and then feed the forestay into the foil
before fitting the lower terminal. If this operation is difficult, reduce friction by applying
washing up liquid to wre before inserting into the sleeve.
The Swivel & Foil End Cap
Slide the swivel (4) onto the foil making sure the outer casting of the swivel is at the top
and the inner casting is at the bottom.
The Foil End Cap (21) consists of 3 parts: an outer plastic end cap and two inner half
bearings (22). Before fitting the end cap, check that the hole in the plastic inner half
bearings is the correct size for the forestay. Drill out if necessary to forestay di
1mm.
Fit end cap to foil as follows: slide plastic end cap over forestay eye terminal* and over
the two profiled plastic half bearings while holding the latter together around the forestay.
Fit bearings into top of foil and rivet the cap to the foil using the two alloy rivets supplied.
