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Summary of Contents for Forespar Leisure Furl OFFSHORE IN-BOOM FURLING SYSTEM
- Page 1 OFFSHORE IN-BOOM FURLING SYSTEM September 26, 2014 Installation Manual...
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Page 2: Table Of Contents
Mainsheet and vang bail fitting Installation – checklist Global agent listing IMPORTANT TOPPING LIFT INFORMATION TO INSTALLERS & OWNERS Your Notes IMPORTANT INFORMATION TO INSTALLERS & OWNERS FORESPAR PRODUCTS CORP. 22322 GILBERTO RANCHO SANTA MARGARITA, CA 92688 PHONE 949-858-8820 FAX 949-858-0505 EMAIL alanm@forespar.com... - Page 3 OF THE BOOM PRIOR TO FASTENING THE VANG LUG AND SHEET BAILS. THIS WILL PREVENT DAMAGING THE SAIL COVER DURING THE DRILL- ING & TAPPING PROCESS. ® Line controlled vangs like the Forespar Yacht Rod should be setup to raise the boom above the 87 angle when the line is released.
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Page 4: Components Packing List
COMPONENTS PACKING LIST 1. Luff track top cap 2. Sail track & Base Extrusion Screws – Inner bearing 3. Flexible feeder Screws – Feeder 4. Furling mandrel Sail Track aligning plugs 5. Outer bearing Seating compound 6. Universal Owners manual 7. -
Page 5: Tooling Required
TOOLING REQUIRED Pencil Paper Hacksaw, including spare blade Scraper Soft hammer Allen key set Hole saw, See Diagram 1 for size Electric drill ½” chuck Electric 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 –... - Page 6 SET UP DIAGRAM For start of base extrusion see chart below 18” Base Extrusion Above Datum Bottom of ‘P’ is the top of mandrel Datum is center of drive shaft Diagram 1 System Shaft size Shaft hole Clearance at Mandrel Datum below Start of base Flexible...
- Page 7 PRE-INSTALLATION INSTRUCTIONS There are three stages to fitting the Leisure furl system. Fitting the sail track Fitting the mast components Fitting the boom and mandrel Each stage is broken into separate step by step instructions, which will guide you through the installation. Before removing or installing any components check this manual to establish if any special instructions have been given for this job.
- Page 8 For installation to a new vessel, the positioning of the gooseneck will be deter- mined as per the information on page 6. It is wise to measure “P” from the top of “P” to the bottom of “P”. This will confirm the gooseneck position as per Diagram 1. In all instances it would be preferable to check with the owner, for the preferred position, because of the greater depth of the boom.
- Page 9 Refer to Diagram 3a and table below for luff track top cap location. This upper reference dimension is from the center of the main halyard sheave down to the top of the base extrusion. SYSTEM SAIL TRACK TOP CAP SERIES REFERENCE DIMENSION 14/5 8.0”...
- Page 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.
- Page 11 INSTALLATION INSTRUCTIONS Flexible feeder limit line fitting instructions – The limit line assembly consists of two stainless steel termination blocks and a fixed length of Spectra line which passes through the eye on the forward face of the luff feeder. To install the limit line termination blocks on the mast, position the port and starboard blocks at an equal distance from the aft face of the mast.
- Page 12 INSTALLATION INSTRUCTIONS – fitting the drive components Find your previously marked datum position. Note : The datum position is the reference for all measurements. Wrap the cardboard straight edge around the mast ensuring that the edges are parallel where they overlap. Tape the ends together, to position securely (See Diagram 6) Align the top or bottom edge of the straight edge with...
- Page 13 Place the inner bearing and spool back in their proper position on the mast. Mark the outer edge of both with a felt marker or pencil. Remove the bearing and spool cover. Cut the masking tape inside the perimeter marks. The area of mast now exposed will be covered with seating compound and the castings.
- Page 14 Wipe off any excess compound from around the drive shaft then refit to the mast. Reassemble the drive assembly. When turned the spool should spin freely. If it does not, remove the spool again and file the edges further. Repeat this until the spool spins freely. In some instances it is possible for a wiring tube to rest against the drive shaft.
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Page 15: Deck Layout
A drill press is preferred when drilling the shaft, but, if drilling through the shaft with a hand drill, make sure to drill at the proper angle so as to pass through the center of the shaft. Use a metal cutting compound to avoid work hardening the drive shaft. You may find it easier to pass through the shaft with a smaller drill first. - Page 16 On new boat installations there is no need for a rope guide, providing a deck block can be located as per diagrams 9 and 12. However with existing boats, depending on the situation the need to centralize the furling line with the center of the spool arises. When used, the rope guide should lead the furling line off the spool parallel to the mast from the spool center as detailed in the diagrams 10 and 11.
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Page 17: Sail Fitting Instructions
Leisure furl Leisure furl Leisure furl Leisure furl Leisure furl Sail fitting instructions INITIAL CHECK Ensure the furling mandrel rotates freely. Ensure the feeder is correctly aligned with the sail track, see diagram 4. Adjust to correct if necessary. Ensure that boom is at correct, 87 degree angle – see owners manual page 5 and 15. SAIL FITTING With the sail laid on the port side, lift the foot up to the furling mandrel, then slide the foot bolt rope into the track, from either forward or aft. - Page 18 Leisure furl Leisure furl Leisure furl Leisure furl Leisure furl Main Sheet and Vang Bail fitting instructions BAIL FITTING When fitting the mainsheet and vang bails in the track the bails must be secured using the special dog set screws that have been provided. Be sure to pull the sail cover to the top of the boom to prevent damage when drilling into the lower cavity.
- Page 19 Leisure furl Leisure furl Leisure furl Leisure furl Leisure furl Checklist after installation If any of the following points are not complete, the system could be damaged. Take care to fix these any outstanding points. 1. Ensure the outer bearing clearance is correct to specifications. (See Diagram 1) 2.
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Page 20: Gilberto
Email arigging@arrakis.es 75007 Paris Ph +33 1 42 22 07 07 UNITED STATES Fax +33 1 42 22 31 31 Forespar Products Corp. Email plemaout@aol.com 22322 Gilberto, Leisure furl International PO Box 22800 Rancho Santa Margarita, CA 92688 Otahuhu Auckland New Zealand Ph +1 949 858 8820 www.leisurefurl.co.nz... - Page 21 IMPORTANT NOTICE TO OWNERS AND INSTALLERS Use caution when topping the aft end of the Leisure Furl boom. As the aft end of the boom is raised, the MANDREL END GAP lessens. Damage, including failure to the MANDREL or the AFT END STRUCTURE can result by compressing the aft end of the MANDREL into the AFT END STRUCTURE.
- Page 22 Leisure furl Leisure furl Leisure furl Leisure furl Leisure furl Sail installation and lashing IMPORTANT NOTE: The clew lashing line must take multiple wraps around the mandrel to eliminate the vertical load component on the pad eye. Damage to the mandrel and the foot of the sail WILL result if this process is not followed.
- Page 23 Important information for both installers and owners. • Do not raise the boom with the topping lift or vang more than 3 feet from the normal operating angle, as the mandrel will bottom out on the boom end plate and cause damage. If it is essential to do this, the mandrel must be disconnected from the universal.
- Page 24 Leisure furl Leisure furl Leisure furl Leisure furl Leisure furl Flex Feeder Leaf Spring This UHMW “Leaf Spring” component provides increased strength and support to the flex feeder at the lower end of the luff base extrusion. The transition from supported to unsup- ported flex feeder has shown to be vulnerable to cracking when the feeder is allowed to flex well beyond its design parameters.
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