in-boom mainsail reefing
Contents
1. 4 Insert the webbing with the tack slide into the port side foot track Please see drawing 15 IV 5 Insert the bolt rope foot tape into the same port side track and gently pull the sail forward IV 6 Once almost at the fore end insert the clew slide 49 into the clew webbing so that the webbing is locked between the two small plastic cylinders of the clew slide 48 and insert the clew slide into the groove of the mandrel 16 Pleas see drawing 16 IV 7 Lock the flat part of the tack slide into the machining of the mandrel groove and pull the sail backwards to lock Please see drawing 15 Drawing 16 19 1 IV 8 Slide the clew 50 with the ring upwards into the foot track ends 16 Please see drawing 16 IV 9 Lash a line between the clew webbing and the ring of the clew pin 50 and tension the foot of the sail Check to tie or cut any loose extra length of lashing line IV 10 Insert the battens into the batten pockets IV 11 Attach the halyard onto the head of the mainsail IV 12 Unscrew by about 3 turns only the port side plastic knob 46 of the feeder 3 to increase the gap between the bronze rollers 40 IV 13 Insert the lt continuous gt port side luff tape between the bronze rollers of the feeder and hoist by hand only a few centimetres of sail IV 14 Slide the starboard side lt head gt luff tape into the starboard luff groove Luff entry for this starboard luff tape is2. 27 1 b Foot tape Maximum finished diameter of 8 mm 5 16 6 TACK AND CLEW REINFORCEMENT a Tack reinforcement Reinforcement patches at the tack are necessary but should add a minimum amount of bulk to this area of the sail b Clew reinforcement A large primary clew reef patch is recommended Take a measurement equal to 25 of the foot length measure from the clew towards the tack amp mark the sail at this point At the 25 mark draw a line parallel to the luff of the sail up to the point where the line intersects the leach A single layer over this entire area will help reinforce the clew and leach when the sail is reefed Additional reinforcement in this area is at the discretion of the sailmaker 7 LEACH REINFORCEMENT AND UV PROTECTION a Leach reinforcement The leach of the mainsail should have a secondary strip approximately 2 feet wide sewn onto the starboard side of the sail This secondary strip will help to strengthen the leach of the sail as well as add additional bulk to the leach By bulking up the leach of the sail the leach will roll tighter and improve the shape of the reefed sail b UV protection A sacrificial strip applied to the starboard side of the sail may serve as dual purpose First to strengthen the leach and also to protect the rolled mainsail from the elements if a UV stable material is utilized By having a sacrificial strip on the starboard side of the leach the need for a formal sa
3. You now release the topping lift 17 MK 1 II 12 ADJUSTING THE POSITION OF THE MAINSHEET BAILS III 12 a Adjust the position of the mainsheet bails 25 with the set screws which can be reached from underneath Fasten the mainsheet blocks on the mainsheet bails CAUTION on boats with a mainsail track or mainsail block attachment on deck ahead of the main hatch the mainsheet bails 25 must be re positioned as far backward as possible III 12 b Push the boom by hand over the lifelines as far as possible and tie a knot on the mainsheet so that in no case the boom profile can be damaged by the rearmost shrouds when running downwind or jibing 13 INSTALLATION OF THE CONTROL LINES TO THE COCKPIT REMINDER TO AVOID FRICTION 1 Only use good quality ball bearing blocks which will have to be cleaned and lubricated from time to time as per manufacturer s specifications 2 Use ball bearing blocks with a sheave of large diameter 3 Reduce as much as possible the number of lead blocks between the drum and the cockpit 4 Reduce as much as possible the angle of deviation of the control lines Ill 13 a Attach the ball bearing block supplied at the mast foot on starboard at the convenient position to lead the line into the middle of the drum at 90 angle 13 b Pass the furling line supplied from underneath through the block then through the hole of the drum s shaft and a tie small knot at its end so that th
4. dition des pi ces avant r ception des pi ces d fectueuses par WICHARD S A S France WICHARD Inc USA ou WICHARD PACIFIC Pty celles ci seront factur es et payables avant l exp dition r glement par carte bancaire transfert bancaire ou tout autre moyen Si la responsabilit de WICHARD est reconnue WICHARD remboursera le client dans les meilleurs d lais LIMITED WARRANTY Your PROFURL product is warranted for a period of 3 three year from the date of purchase against parts and materials This warranty is limited to the repair and replacement of defective parts by an authorized PROFURL dealer and only after the written consent of WICHARD 5 5 France WICHARD Inc or WICHARD PACIFIC addresses below The warranty is void if the system is modified or repaired prior written consent of WICHARD S A S France WICHARD Inc WICHARD PACIFIC This warranty covers only the WICHARD parts and materials Any accidental damage or expenses are not covered by the warranty This warranty does not cover damages caused by a system which was installed or used improperly damaged by collision or any act of God In the event of a warranty claim WICHARD s liability is limited to the value of the system at the date of purchase Packaging costs shipment or custom charges are at customer s expense WHICH PROCEDURE SHOULD YOU FOLLOW IN CASE OF WARRANTY CLAIM case it is impossible for the owner to have the damage checked by a skilled person
5. had been re cut 9 1 cut the boom profile 15 the mandrel 16 to length first dismantle the rear boom end fitting 23 from the boom profile and pull out the mandrel 16 from the boom profile Caution during dismantling the mandrel 16 will not be held any more Please keep control about the mandrel potentially falling down when pulled backwards Also mind not to lose the washer 20 located forward of the drum 24 13 1 III9 a 2 To re cut the boom profile 15 to length and to make sure that the cut section is accurately perpendicular to the profile wrap a sheet of paper or mylar with accurate right angle corners so that the edges are in perfect line and attach it with adhesive tape Please see drawing 10 Draw a line on the boom profile following the edge of the sheet where the boom profile will be cut III9 a 3 Cut the boom profile according to the line and file edge smooth Drawing 10 Draw along the edge Paper or mylar sheet 14 1 9 b CUTTING THE MANDREL LENGTH The mandrel 16 should be re cut by exactly the same amount as the one having been cut off from the boom profile Example if you have re cut 312 mm from the boom profile you should also re cut 312 mm from the mandrel III9 b 1 Remove the bearing holder 19 bearing 18 assembly from the rear end of the mandrel 16 III 9 b 2 Cut the mandrel 16 at its rear end with the same procedure as the o
6. sail to furl properly and may damage the reefing furling system Please refer to drawings 3 4 and 5 for specific detail 4 LUFF TAPE ASSEMBLY a Primary luff tape Teflon luff tape with a finished diameter of 5 mm 3 16 is recommended for the luff of the sail Attachment of the luff tape should be performed with the sails final luff curve Luff tape should have only one seam immediately aft of the bolt rope and fit to the sail with the bolt rope immediately aft of the bolt rope and fit to the sail with the bolt rope against the cut luff curve of the sail Caution Luff tape applied to a sail based on a luff curve drawn onto the sail may shorten the life expectancy of the luff tape Also luff tape with a secondary seam aft of the primary bolt rope seam may require replacement sooner than the recommended type b Secondary luff tape at head In order to better distribute the potentially high leach loads induced into the head of the sail a secondary luff tape is sewn onto the starboard side of the sail The secondary luff tape should be between 200 mm and 500 mm 8 and 20 Seaming of the secondary luff tape must not be closer than 33 mm 1 5 16 from the leading edge of the luff tape Please refer to drawing 6 for further detail 5 LUFF AND FOOT TAPE DIAMETER a Primary and secondary luff tape Maximum finished diameter of 5 mm 3 16 Teflon luff tape is recommended to minimize friction when hoisting and striking the sail
7. the owner will contact WICHARD S A S France WI CHARD Inc USA or WICHARD PACIFIC Pty Ltd Please see address below defective part should be returned at owner s expenses to WICHARD S A S France WICHARD Inc or WICHARD PACIFIC Pty Ltd within 14 fourteen days after the damage occured to the system case the parts are shipped from a country outside France USA or Australia custom duties for return to WICHARD should be prepaid by the owner case the owner will demand urgent replacement of part before the defective part is received by WICHARD the replacement part will be charged to the owner and paid before shipping credit cards accepted In case WICHARD s responsibility is finally acknowledged WICHARD will refund the owner replacement part purchased from a PROFURL dealer will be refunded to the owner In the normal warranty procedure the parts will be returned to the owner shipping and customs at owner s expenses www profurl com WICHARD France WICHARD Inc WICHARD PACIFIC Pty Ltd Hotline Support technique SAV 148a Bryce Blvd Unit 13 2 Bishop Street 33 de l Etoile du matin Fairfax VT05454 St Peters NSW 2044 44600 Saint Nazaire USA Australia France Tel 1 401 683 5055 Tel 61 2 9516 0677 Tel 33 0 2 51 76 00 35 Fax 1 802 655 4689 Fax 61 2 9516 0688 Fax 33 0 2 40 01 40 43 Free toll number 1 800 852 7084 Freecall from Australia 1800 639 767 Email hotline w
8. 8 Rear boom end fitting with pin and pop rivets 50603 Pop rivets 4 8 X 14 TR 177015 Rear bushing kit 50461 Bearing holder 50455 50462 Washer LN 16 P177016 Tack slide P177017 Clew slide P177019 P177024 Mainsheet bail 02346 Set screw 5 M8 x 8 01659 Mainsheet bail onl 50360 Ball bearing block 50344 8 mm 5 16 furling line 50713 Recommended operating procedure P51235 13 1 1 2 boom brake 203 C model Designation BOOMVANG AND ACCESSORIES BOOMVANG ATTACHEMENT P181210 Boomvang attachment P177038 Slide screw for rectangular track and locknut P177039 Slide screw for round track and locknut 50463 Boomvang attachment only or gooseneck 50456 Boomvang or gooseneck attachment sideplates 50486 Pop rivet 4 8X16 TF 52918 181211 Complete articulation 50803 Articulation eye 51065 Large PE pin washer 50011 Small PE pin washer 00095 SS washer 12 50940 Low aspect nut H M12 00094 Locknut H M12 50489 1 25 1 MAINSAIL REEFING FURLING SYSTEM 1 MAINSAIL DESIGN SPECIFICATIONS 1 GEOMETRY The design of the mainsail is very critical to the proper operation of the ProFurl In Boom Reefing Furling system General design requires a slightly flatter sail than normal with a minimum luff curve built into the sail to ensure proper rolling of the sail onto the furling mandrel and into the boom cavity a Luff curve design A straight luff is by far the most optimal for rolling the sai
9. D FITTING THE UPPER CUT LUFF PROFILE III 7 a Accurately measure the length A to D gt Please see drawing 8 III 7 b Mark length to D on the remaining luff profile 2 and cut it at this exact length File smooth the cut edge Note in case of a very flexible mast or fractional rig cut profile at A to D minus 15 mm and leave the 15 mm as a play between the cut edge of the profile and A III 7 c Fit without tightening the 2 set screws 9 on the threads located at the opposite side of the cut end III 7 d Hoist the cut luff profile 2 8 FITTING THE UPPER CUT LUFF PROFILE ONTO THE SHEAVE BOX III 8 a Slightly ease the 4 slide screws 7 which hold the upper end brackets 6 and remove the sheave box 11 lll 8 b Insert the striped aluminium bar of the sheave box 11 into the cut end of the luff profile 2 Note in case of a very flexible mast or fractional rig leave 15 mm play between the top end of the profile and A 8 c Insert the bottom end of the luff profile 2 into the uppermost connector articulation 4 III 8 d Fit again the sheave box 11 onto between both end brackets 6 and fasten the 4 slides screws 7 to permanently secure this assembly lll 8 e Tighten the set screws 9 at the bottom end of the cut luff profile 2 III 8 f Follow the path for the mainsail halyard as shown on drawing 7 12 MK 1 Ill 9 CUTTING THE BOO
10. M PROFILE AND THE MANDREL TO LENGTH 9 HOW TO CALCULATE THE LENGTH OF THE BOOM PROFILE Case 1 The PROFURL boom overall length should be the same as the one of the original boom Case 2 The PROFURL boom being delivered in over length the opportunity may be taken to make the boom longer Caution changing the boom length could affect the balance at the helm when sailing under sails In this case check that the aft end of the boom cannot touch the backstay or any other piece of equipment on board In both cases please refer to drawing 9 for dimensions a 100 mm 3 5 16 Le 406 ou 5016 mn 132 7 64 or 165 31 64 gs SSE s 2 gyal grater y pet Et T 7 3 1 i vs nues RE 1 2 oe a Mm j 4000 oy S000mm 13 1 31 66 or 85 27 32 Kine 139 7 l6 or 17 ir ss 5 5 8 4202 ou 5702 139 7 16 or 17 13 16 1 The PROFURL in boom reefing system is delivered pre assembled and in over length The boom profile 15 and the mandrel 16 will probably have to be re cut to length to match the boat s requirements when fitting the system CAUTION should the complete length of the boom profile be used the rear boom end fitting is just temporarily attached to the boom profile for shipping Please follow the fitting procedure from 11 9 c 7 and on as if the boom profile
11. MK 1 08 03 02 PROFURL IN BOOM REEFING SYSTEM MK 1 INSTALLATION MANUAL IMPORTANT NOTICE TO RIGGERS PLEASE GIVE THIS MANUAL TO THE BOAT OWNER AND ASK HIM HER TO CAREFULLY READ IT BEFORE USING THE SYSTEM RECEIPT OF GOODS All goods must be checked on delivery and the Buyer should claim from the carrier verbally within three days in the event of loss or damage and in writing within seven days 1 Congratulations for the purchase of your PROFURL in boom reefing furling system Please read carefully this manual It will give you to all information for fitting and using your system in order to give you many years of dependable service IMPORTANT WARNING FOR USING YOUR SYSTEM g The PROFURL boom is obviously heavier than your conventional boom Do not make uncontrolled gibing specially with strong wind as you could permanently damage your system Reminder to gibe 1 take in or winch your main traveller and main sheet 2 turn your boat to gibe 3 gradually release your main traveller and main sheet You can even better fit a tackle as boom preventer please see drawing A boom brake is supplied with your system it must be used and adjusted at any time You should not forget to completely release it each time you want to operate your system 1 5 2 Important warning to use your system Page 3 Preliminary cautions Page 4 General description Page 5 Exploded view
12. NFITTING THE HARDWARE FROM THE MAST Il 1 a Dismantle the original gooseneck as well as cleats winches and winches brackets on the mast as well as any piece of equipment which would interfere with the fitting of the new gooseneck and with the ability for the forward boom end fitting to rotate when the boom should swing from one side to the other Please see III 1 b and drawing 1 for dimensions of the new gooseneck in relation with mark the mast Il 1 b The original boomvang attachment should not be used as the axis of rotation of the boom and of the new gooseneck need to be in line which would never be the case with the original boomvang fitting ll 1 c Dismantle the original feeder if any at the mast track entrance II 1 d Check that the slide screws 7 supplied have suitable dimensions for the mast track If not their width should be modified turned machined grinned filed accordingly 7 SLIDE SCREWS Width reduced if nerecsaarv In all other cases please contact us 1 INSTALLATION 1 DETERMINING THE HEIGHT OF THE GOOSENECK III 1 a To avoid any potential conflict between the boom and the cabin top a bimini lifeline or any other piece of equipment please accurately mark the level of the lower edge of the original boom Please see drawing 1 lll 1 b Check that the boomvang delivered with your system will make once installed an angle of minimum 30 with the mast an
13. OFURL USA 3 This warranty covers only the PROFURL parts and materials Any accidental damages expenses are not covered 4 This warranty is void if the system is modified or repaired without prior written notification to PROFURL France USA 5 This warranty does not cover damages caused by systems which has not been properly installed 6 This warranty does not cover the misfunctionning of the system due to a sail having been made without strictly following the attached specifications 7 After installation the customer should check the following the sail dimensions are accurately adapted to the system s dimensions the sail has been designed and made according to the attached specifications all screws are properly tightened the various fitting procedures and adjustments described in this manual are strictly followed Please return this portion within 15 days of purchase to PROFURL 7 1 des Marais 32 rue des Osiers 78310 COIGNIERES France Boats TS Boat s lengt n y a E a Boat s Mainsail s luff length Mainsail s foot Installed aaia e a m in Pate a Su a aa aa Owner s signature 23 1 SPARE PARTS LIST Bushing for connector articulation Slide screw fo
14. Page 6 Tools needed for fitting Page 6 Unfitting the hardware from the mast Page 7 Determining the height of the gooseneck Fitting the slide screws in the mast track Page 8 Fitting the gooseneck Page 8 9 Assembling the luff profiles Page 10 11 Fitting the articulation brackets onto the mast the sheave box Page 12 Measuring and fitting the upper luff profile Fitting the upper luff profile onto the sheave box Page 13 14 Cutting the boom to length Page 15 Cutting the mandrel to length Fitting the mandrel onto the boom Page 16 Fitting the boom onto the gooseneck Page 17 Fitting the boomvang hound the boomvang Page 18 Adjusting the position of mainsheet bails Installation of the control lines to the cockpit Page 19 Fitting the mainsail Page 20 Feeder adjustment Page 21 Adjusting the boom angle to the mast Page 22 Using the system Limits for using the system Page 23 Warranty Page 24 25 Spare parts Pages 26 Mainsail design specifications PRELIMINARY CAUTIONS The PROFURL in boom mainsail reefing system is not designed to be installed on wooden masts or aluminium masts with track added with screws rivets glue any similar assembly Fitting on a carbon mast is not recommended an requires special skills Please contact us Please check that there is no sign of severe corrosion on the mast which would compromise the strength of the assembly The person in charge with fitting will be fully responsible for installation and ad
15. aptation on board according to the specifications shown in this manual 1 I GENERAL DESCRIPTION Note names in bold refer to parts identified on next page The PROFURL in boom furling system includes One set of luff profiles 1 and 2 articulated on the aft face of the mast There are 2 different kinds of luff profiles one 0 60 m long feeder profile 1 on which the feeder 3 is attached and several 2 meters long normal luff profiles 2 depending on the mainsail s luff length One of these 2 meters long normal luff profiles 2 will be re cut to length _at its upper end to match the expected luff length of the boat The different luff profiles 1 et 2 are connected to each other by mean of connectors articulations 4 which are connected to articulation brackets 5 attached on the aft face of the mast CAUTION the articulation brackets 5 have stainless steel pin Check the difference with end brackets 6 which have Nylon flanges 55 2 Articulation brackets 5 attached to the mast with 2 slide screws 7 slipped in the mast groove Every slide screw 7 has a thread and a flat end going through a hole of the articulation brackets 5 The thread of the slide screws 7 receives a washer 33 and locknut 8 for attachment 3 Connectors articulations 4 also used to connect the different luff profiles 1 and 2 held by set screws 9 The lower end of the 0 60m long feeder profile 1 will be connecte
16. d on the gooseneck articulation 10 thus allowing the luff profiles 1 and 2 to rotate together with the boom 4 A sheave box 11 through which the mainsail halyard is passing The sheave box 11 will be fit at the top of the luff profiles 1 and 2 It is assembled on the end brackets 2 times 6 themselves being attached by mean of slide screws 7 and locknuts 8 5 A gooseneck 12 fit on the mast with 2 slide screws 7 and 2 gooseneck plates 13 cambered at the mast shape before fitting and which will be riveted onto the mast with the conical head pop rivets 14 supplied 6 A boom profile 15 which has been delivered either in 4 or 5 meters It may be re cut to length when fitting to match the expected boom length 7 A mandrel 16 which turns on bearings 17 and 18 fit bearing holder 19 at the rear end of the boom and on the drum bearing holder 21 front turning around a pin inserted in each of the boom end fittings 22 and 23 When re cutting the boom profile 15 to length the mandrel 16 should also be re cut 8 A drum boom end fitting 22 It includes the drum 21 fit onto the mandrel 16 the drum being loaded with the furling line supplied by pulling on the furling line and releasing the mainsail halyard it will rotate the mandrel which will furl the sail 9 2 adjustable mainsheet bails 25 More mainsheet bails are optional 10 A special boomvang 27 It is attached onto the mast by mean o
17. d the boom Should it not be the case the position of the new gooseneck must be fit higher on the mast in order to obtain this minimum 30 angle Information pin to pin boomvang length 1400 mm open 1305 mm closed lll Draw a line lt C gt on the mast at the level of the lower edge of the original boom Please see drawing 1 III 1 d Draw a line on the mast at 364mm 1 2 21 64 above line The line B will correspond to the level of the upper edge of the gooseneck plates 13 once fit on the mast 3 ORIGINAL BOOM LEVEL REFERENCE T cee A LOWER EDGE OF ORIGINAL BOOM lil 2 FITTING THE SLIDE SCREWS INTO THE MAST TRACK III 2 a Insert the head of the slide screws 7 into the mast track The number of slide screws you need to insert depends on the number of articulation brackets A two slide screws are needed for the boomvang attachment Slide these slide screws down to the mast foot to later fit the boomvang attachment 11 and drawing 13 Slide four slide screws 7 into the mast track for the upper end brackets 6 C Slide as many times two slide screws 7 into the mast track as the quantity of articulation brackets 5 to be fit Please see drawing 5 Ill 2 b Move the stacked slide screws mentioned in above B and C upwards onto the mast above the mast track opening and temporarily hold them with adhesive tape to prevent
18. e knot will be completely hidden inside the drum s shaft Please see drawing 14 Drawing 14 III 13 c To fill the drum with line turn the mandrel 16 by hand towards port side seen from above so that the furling line exits from the drum on the starboard side III 13 d Fit another ball bearing block at the mast foot to lead the mainsail halyard to the cockpit Remind to use the right type and dimensions of blocks Ill 13 e Check that the exit from the mast of the mainsail halyard does not bring too much chafe 18 1 IV FITTING THE MAINSAIL Please check again that the foot tracks have been filed smooth at the rear cut end before starting inserting the foot tape of the sail CAUTION before operating the PROFURL in boom reefing system please make sure that 1 the mainsail construction and design are in accordance with the attached specifications Please refer to the attached mainsail design specification 2 the boomvang angle adjustment please see VI is correct This adjustment is an essential point to get a good quality furling of the mainsail as well as ease of operation IV 1 Turn the mandrel 16 by hand so that the tracks please see drawing 15 are upwards IV 2 Do not yet insert the mainsail battens into the batten pockets IV 3 Insert the tack slide 48 into the tack webbing with the flat part backwards and lock the webbing ahead of the two small plastic cylinders Drawing 15
19. e la garantie l gale votre produit PROFURL est garanti 3 trois ans partir de la date de mise en service la facture d achat au revendeur ou au constructeur faisant foi La garantie se limite au remplacement ou la r paration en nos ateliers des pi ces reconnues d fectueuses La garantie dispara t imm diatement et compl tement si le client modifie ou fait r parer sans l accord Wichard le mat riel fourni La r paration la modification ou le remplacement des pi ces pendant la p riode de garantie ne peuvent avoir pour effet de prolonger le d lai de garantie du mat riel La garantie ne couvre pas les dommages cons cutifs un mauvais montage une utilisation inappropri e ou abusive un accident ou toute fortune de mer PROCEDURE A SUIVRE EN CAS D APPEL EN GARANTIE En cas d impossibilit de faire constater par une personne comp tente la nature des dommages le client prendra contact directement avec WICHARD S A France La ou les pi ce s d fectueuse s devra devront imp rativement tre retourn e s pour inspection WICHARD 5 5 France WICHARD Inc aux USA ou WICHARD PACIFIC Pty Ltd port aux frais du client dans les 14 quatorze jours suivant le constat de l avarie En cas de r exp dition du mat riel depuis un pays tiers les frais de d douanement ventuels correspondant en France ou aux USA restent la charge du client Au cas o le client exige une r exp
20. eck From this stage and on the luff profiles must turn together with the boom 1 Drawing 12 30a CUT PROFILE 2 8 25 16 Split 16 1 11 FITTING THE BOOMVANG HOUND AND THE BOOMVANG not angle less than 30 with the mast or boom III 11 a Fit the boomvang attachment fitting 56 with the two slide screws which had been stored at the mast foot III 2 B III 11 b Bend the aluminium gooseneck sideplates 13 with clamps to accurately camber them to the mast shape During bending please protect the plates from dings and dents III 11 c Would the sideplates be too long they can be re cut if necessary keeping in mind too much length is always better than too little III 11 d Draw lead lines for drilling on the side plates 13 Drill at 5 mm and machine holes so that the conical heads of the pop rivets 14 will be flush with the surface of the side plates There should have at least 12 pop rivets 14 on each side plate III 11 e Fit the stickers 33 onto the plates to hide the head of the pop rivets Do the same for the gooseneck plates please see S III 3 III 11 f Fit Nylon washer 29 onto the pin of the articulation eye 49 Fit pin into the gooseneck attachment fit the washers 30 and 29a and locknuts 31 and 30a 11 g Fit the boomvang onto the articulation eye 49 and onto the boomvang hound 28 Fit the pins and the split pins 33 22 Drawing 13
21. ert the rear boom end fitting over the rear cut end of the boom profile 15 Tip A ratchet tie down strap is a handy tool to do this III 9 c 6 Drill holes 2 5mm at the rear end of the boom profile 15 through the pre drilled holes of the rear boom end fitting 23 Fit the corresponding flat head pop rivets 24 supplied in these holes to permanently attach the boom end fitting onto the boom profile 16 9 12 23 Drawing 11 28 25 15 1 10 FITTING THE BOOM ONTO THE GOOSENECK 10 a Hoist the boom with halyard and a topping lift drawing 12 by keeping it as horizontal as possible Pull it backwards at the same time III 10 b Slide from underneath all together same as III 3 e 1 the vertical aluminium striped bar of the gooseneck articulation 10 into the bottom end of the feeder profile 1 2 the vertical stainless steel pin of the gooseneck articulation 10 into the corresponding vertical hole of the gooseneck fitting 12 10 c Fit the nylon washer 29a onto the vertical stainless steel 10 Insert vertical pin into the gooseneck fitting 12 Fit stainless steel washer 29 on the thread Permanently fit and tighten with a 19 mm tube or ratchet wrench onto the thread the low aspect locknut 31 and Nylock 30a Fit the plastic cap over the Nylock Caution do not drop or raise the boom more than 15 from horizontal position as it could cause permanent damage to the goosen
22. f aboomvang attachment including an gooseneck 12 attached onto the mast with 2 slide screws 7 locknuts 8 and 2 gooseneck plates 13 which will be riveted on the mast with pop rivets 14 with conical head supplied The boomvang lower end will be attached onto an articulation eye 49 rotating in the boomvang gooseneck 56 onto the boom with a boomvang hound 28 11 A ball bearing block 52 to lead the furling line 51 to the cockpit 12 A boom brake 1 TOOLS NEEDED FOR In all cases of fitting measuring tape m An electric drill m A set of drills m A hack saw with new blade with small teeth m A file m pencil m plastic hammer m A 13 mm pipe wrench m A 19 mm pipe wrench m dynamometrical wrench 1daN m 1 set of Allen wrenches supplied 2 clamps with opening 300 mm Universal pliers m A cutter blade with new blades A large sheet of paper with corners perfectly at 90 and adhesive tape Several small plywood or rubber shims m A pop rivet gun for 5 mm stainless steel rivets Note the plates to fit the gooseneck and boomvang attachment are 8 mm thick and made out of aluminium A convenient hydraulic or mechanical press should be used to bend them at the mast shape fitting them on the mast with the clamps If the fitting is made on a standing mast Boson s chair Some short ropes of 8 or 10 mm diameter Il PREPARATION II1 U
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24. il cover is eliminated Note The sacrificial UV strip must be wide enough to completely cover the sail when rolled onto a 70 mm 23 mandrel tube 28 1 4 MAINSAIL LUFF CURVE DESIGN Drawing 19 STRAIGHT LUFF FROM 75 AND UP LUFF CURVE NOT ROACH NOT TO EXCEED TO EXCEED 25 FROM 6 OF LEECH LENGTH MAST PRE BEND INVERSION OF LUFF CURVE AT 40 FROM TACK j CURVE CHANGE AT 20 FROM TACK FOOT CURVE 1 OF E 29 MAINSAIL BATTENS ANGLE TO THE LUFF CONSIDERED AS A STRAIGHT LINE Drawing 20 MK 1 30 MK 1 BATTEN POCKETS CONSTRUCTION Drawing 21 PATCH BATTEN POCKET VAN LUFF TAPE 13 64 FINISHED 05 wrt we s 4 5 16 mini 33mm mini 51 23 64 X CLEW Drawing 22 i 732 1 17 64 1 32 gt WIDE WEBBING 25mm TACK Drawing 23 5 16 8mm FINISHE DIAMETER MK 1 33 1 HEAD CONSTRUCTION Drawing 24 WEBBING STRAP SECONDARY SHORT LUFF TAPE ON STARBOARD SIDE 1 2 LUFF TAPE PRIMARY CONTINUOUS z LUFF TAPE ON PORT SIDE Sje E SECONDARY 5 19 LUFF ON EES STARBOARD SIDE SEWING OF SECONDARY LUFF TAPE PRIMARY LUFF TAPE ON PORT SIDE 34 CONDITIONS DE GARANTIE Sans pr judice d
25. inished diameter of 8 mm 5 16 d Roach Maximum positive leach curve should not exceed 6 of the leach length If a fuller roach is desired additional reinforcement will be necessary at the forward end of the batten pockets and may not allow the luff of the sail to set properly in light air Also the added load on the battens may accelerate luff tape wear 26 1 2 Battens a Number and type of battens 4 semi full length battens are recommended Additional battens may be added but keep in mind that additional battens create more bulk to the sail and will limit the ability to furl max luff length into the boom cavity Semi flat tapered battens may be used if desired but may also add additional bulk to the sail b Batten pocket positions Batten pockets should be sewn on the port side of the sail and be of standard design based on the type of battens being used Reinforcement of the batten pocket at the luff must not be closer than 33 mm 1 5 16 to the leading edge of the luff tape see drawing 2 Leach end of the batten pockets may be finished in the sailmakers preferred style Please refer to drawing 1 for batten pocket angles Note batten pocket angles are based on a straight luff curve 3 HEAD TACK AND CLEW ASSEMBLY Only webbing straps of 25 mm 1 and a two ply maximum thickness of 3 mm 7 64 should be used at the tack and clew of the sail Metal grommets should not be utilized as they will not allow the
26. l but not necessarily the best for sail shape To compensate for various rig designs and mast prebend a maximum of 2 inches of luff curve may be designed into the mainsail Further draft must be built into the sail through the broad seams Caution if the 2 inches luff curve is exceeded it is possible the sail will not roll properly into the boom cavity b Draft As with any furling sail the draft of the mainsail must be flatter than with a conventional mainsail Leach broad seaming should remain normal with primary changes to the luff broad seams A maximum draft of 8 may be used on a standard furling mainsail This design will offer the most optimal sail shape for reefing and furling the mainsail If a deeper draft is desired for better light air performance a sail shaping item such as foam pad must be added to the foot of the sail The foam pad is designed into the foot of the sail under the same theory as a foam pad is added to the luff of a reefing furling headsail Shape of the foam pad will be determined by the depth and position of the mainsail draft Caution Increasing the draft above 8 may create a less desirable sail shape when reefing the mainsail c Tack angle and foot curve The tack angle based on a straight luff and foot must be cut at 88 Minimum foot curve should not exceed 0 5 of the foot length at mid length of the foot Please refer to drawing 1 The finished foot of the sail should be a bolt rope with a f
27. located just above the feeder 3 at the connector level V FEEDER ADJUSTMENT The feeder has features allowing to very accurately trim the gap between the 2 bronze rollers 40 to exactly match the bolt rope diameter to quickly increase the gap between the bronze rollers to easily insert the bolt rope luff tape into the groove of the luff profiles after the sail has been furled or removed to instant bring back the correct gap for feeding the sail into the groove of the luff profile to use the system V 1 ADJUSTMENT OF THE GAP BETWEEN THE ROLLERS PLEASE SEE DRAWING 17 V 1 a Completely screw by hand but do not over tighten the port side knob 46 of the feeder V 1 b Release screw 63 V 1 c Adjust the starboard side plastic screw 41 with the adjustment tool 67 inserted into the holes of the screw s flat head till feeling that the luff tape in pinched Then unscrew it back by about 1 4 of turn to make the luff tape free to slide up and down The adjustment is now correct Lock again screw 63 V 1d Hoist the sail by gently pulling on the halyard V 1e To lower or furl the sail release the halyard Drawing 17 20 1 V 2 TO INSERT THE BOLT ROPE INTO THE FEEDER V 2 a Unscrew the port side plastic knob 46 by a few turns to increase the gap between the bronze rollers 40 V 2 b Insert the bolt rope luff tape between the 2 bronze rollers 40 and push it upwards into the
28. ne having been used for cutting the boom profile 15 same as III 9 a 2 File smooth the rear cut end of the mandrel and foot track ends Caution the forward drum end of the mandrel 16 must not be cut III9 b 3 Fit again the bearing 18 and bearing holder 19 into the cut rear end of the mandrel Tap a thread at M6 6mm at opposite from the grooves at 25 mm 1 from the cut end Fit and tighten screw 38 III9 b 4 In case the mandrel has been cut a little too short the fore and aft play must be reduced to a minimum To do this loosen the screw 38 push the mandrel forward pull out the bearing holder 19 so that the washer 20 touches backwards tighten again screw 38 III9 c FITTING THE MANDREL ONTO THE BOOM II9c1 Before fitting the mandrel 16 into the boom profile 15 turn the boom upside down to fit the gooseneck articulation 10 onto the drum boom end fitting 22 with the pin 34 and open the split pin 35 III 9 c 2 Fit the mandrel 16 into the boom profile 15 fit the washer 20 and the drum bearing 18 onto the stainless steel pin 36 inserted in the drum boom end fitting 23 III9 c 3 Check that the mainsheet bails 25 and boomvang hound 28 are properly fit in the bottom track of the boom as shown on drawing 11 III 9 c 4 Slide the bearing 18 located at the rear end of the mandrel 16 onto the stainless steel pin inserted in the rear boom end fitting 23 III9 c 5 Completely ins
29. nsion it VIII LIMITS FOR USING THE SYSTEM IN RELATION WITH APPARENT WIND Some boats have spreaders at 90 from boat s centreline some other spreaders angling backwards Some other have aft shrouds In these last cases the sail will drag on the standing rigging earlier than with boats having spreaders at 90 This means that the sailcloth will touch the standing rigging sooner or later depending on each boat A smooth operation is obtained as long as the sail is not touching any shroud or spreader when the mainsheet is completely released In other terms it is necessary to come into the wind to reef or furl the sail just as you would have done with conventional mainsail reefing However in case of emergency the sail can be rolled at larger angles to the wind till the stage when the friction on the standing rigging will make the system more and more difficult to operate Friction would also obviously increase with the wind s speed In this case a smooth furling can t be guaranteed 22 1 WARRANTY 1 The PROFURL in boom reefing system is warranted for 3 years from date of purchase against parts and materials provided the warranty card is returned within fifteen days from date of purchase The warranty covers the original owner and is not transferable 2 The warranty is limited to the repair and replacement of defective parts only by an authorised PROFURL dealer and only after the written consent of PROFURL France or PR
30. on brackets 5 Please see drawing 5 e the sheave box 11 Please see drawing 6 e all the slide screws 7 to be slipped upwards in the mast track and locknuts 8 1 Ill 5 FITTING THE ARTICULATIONS BRACKETS ONTO THE MAST Ill 5 a Consider the 2 lower slide screws 7 stacked above mast track entrance III 5 b Fit an articulation bracket 5 onto these slide screws with the stainless steel pin pointing upwards please see drawing 5 and completely insert the Nylon bushing of the connector articulation onto the stainless steel pin 5 c Fit washers 33 and locknuts 8 onto the thread of the slide screws 7 Tightening torque should be 1 to 1 5 daN m Caution during fitting the articulation brackets 5 onto the connector articulations 4 permanently check that the feeder profile is indeed fully inserted into the gooseneck articulation 10 Please see drawing 4 III 5 d Fit all the articulation brackets 4 with the same procedure G ass steel pin 6 FITTING THE SHEAVE BOX lll 6 a Slide up in the mast track the 4 remaining slide screws 7 Ill 6 b Temporarily fit the 2 end brackets 6 and the sheave box 11 so that the rear upper of the sheave box leaves a minimum clearance of 20 mm with the backstay s Please see drawing 7 10 1 Draw a line gt on the mast corresponding to the position shown on drawings 7 and 8 11 1 II 7 MEASURING AN
31. oom with the mainsheet The boom brake supplied with the system must be adjusted and used at any time as per manufacturer s specifications It should be released each time you want to operate your system Rules of thumb 1 Make the boat s angle with the wind corresponding to a broad reaching or closer to the wind 2 Before using the system completely release the mainsheet so that the boomvang push effect brings back the angle between the boom and the mast to its lt operating gt position 3 H the mainsail is not properly do not attempt to correct this immediately but hoist the sail completely check points as per S VI 6 and try again After a short period of time you will feel how much drag is to be given to the halyard to get the right tension to obtain a smooth furling of the sail During hoisting the sail a slight drag should be applied to the furling line in order to allow the furling line to be rolled tight enough in the drum this will make next furling easier Should you wish to just a reef your sail please carefully check that the head of the sail is just above a connector articulation in order to prevent the luff profile to sag too much Please stick insignia reefing marks on the luff of the sail which will be at feeder level to show when the head is at the convenient position When in harbor or sailing under power please remove the halyard from the head of the mainsail attach it onto the rear end of the boom and te
32. port side luff track V 2 c Completely tighten by hand without over tightening the port side plastic knob 46 V 2 Insert the starboard side bolt rope luff tape directly into the starboard luff track above the feeder Please see drawing 18 V 2e The mainsail is now ready to be hoisted Drawing 18 VI ADJUSTMENT OF THE BOOMVANG ANGLE TO THE MAST This essential procedure must be achieved either with no wind at all or with extremely calm wind and the boat heading into the wind 1 Hoist the sail as previously described and tension the halyard normally VI 2 Completely loosen the nuts of the boomvang hound 28 and make sure the hound is totally free to move fore and aft VI 3 Make sure the mainsheet is completely loose and let the boom hang in this position VI 4 Re tighten the nuts of the boomvang hound 28 with the boom in this position 5 The sail can now be furled by gently releasing the halyard and pulling together on the furling line VI6 Fine tuning of the boomvang position adjustment may be necessary If the luff tape rolls too much backwards adjust the boomvang hound 28 position so that the boom angles up a little more If the luff tape rolls too much forward adjust the boomvang hound position so that the boom angles down a little more 21 1 VII USING THE PROFURL REEFING SYSTEM IMPORTANT WARNING when gibing please keep constant control of the b
33. r rectangular track and locknut Slide screw for round track and locknut Complete tutt prote Complete connector articulation Bushing for connector articulation Slide screw for rectangular track and locknut Slide screw for round track and locknut 50453 Feeder profile only P177035 Complete feeder 50451 Feeder housing Feeder rollers adjustment screw starboard side Feeder rollers adjustment knob port side Feeder rol Pop rivet 4 X 13 5 TR PE screw M6 x 6 Adjustment feeder tool Complete gooseneck Gooseneck or boomvang attachment only Kit sideplates screw and pop rivets stickers Gooseneck or boomvang sideplates Slide screw for rectangular track and locknut Slide screw for round track and locknut Complete gooseneck articulation Complete lower ending bearing holders 50901 Gooseneck articulation only Gooseneck with split Drum boom end fitting with Drum boom end fitting only Assembling pin for drum boom end fitting Complete boom profile 4m Drum boom end fitting with pin Complete boomvang hound 02346 SetscewSTHc P177012 _ Drum only P177024 Mainsheet bail 177130 Complete boomvang hound 50538 Boom profile 5 m 16 4 3 4 50540 Mandrel for 5 m 16 4 3 4 boom 02346 Set screw STHc 50830 Tube 1 2 for rainwater catching P177012 Drum only P177014 Drum bushing and washer 50460 50462 Washer LN 16 02346 Set screw 5 M8 x 8 P17701
34. round III 4 a Fit the luff profiles 1 et 2 together starting with the feeder profile 1 where the feeder 3 is attached to The lower end of this feeder profile can be identified by the luff grooves have been machined off Please see drawing 2 Luff grooves machined off III 4 b Completely insert a connector articulation 4 at the upper end of the feeder profile 1 so that the Nylon bushing is turned towards the lower end of the feeder profile Please see drawing 4 lll 4 c Fit and tighten the set screws 9 at the upper end of the feeder profile III 4 d Fit a 2 meter long normal luff profile 2 onto the connector articulation 4 which has been fit as above Caution check again that the collars of the Nylon bushings 57 of the connectors articulations 4 are turned towards the lower end of the luff profiles column 1 lll 4 e Fit and tighten the set screws 9 onto the luff profiles Fit with the same method all the luff profiles 2 except the last 2 meter normal profile Please see drawing 7 Ill 4 f Hoist the above luff profiles column from the aft side of the mast by preferably using the existing topping lift III 4 g Completely insert the lower end of the feeder profile 1 into the striped aluminium connector of the gooseneck articulation 10 Please see drawing 4 Ill 4 h Climb the mast taking with you e the two end brackets 6 Please see drawing 6 e all the articulati
35. them slipping out of the track Ill 2 c Slide 2 extra slide screws 7 into the mast track for fitting the gooseneck 1 3 FITTING THE GOOSENECK a Attach the gooseneck 12 to the mast track at the convenient height 1 with the 2 corresponding slide screws see 2 and corresponding locknuts 8 Tightening torque must be 1 to 1 5 daN m Please see drawing 4 lll 3 b Bend the aluminium gooseneck sideplates 13 with the clamps to accurately camber them to the mast shape During bending please protect the plates from dings and dents III 3 c Screw the sideplates 13 onto the gooseneck Would the sideplates be too long they can be re cut if necessary keeping in mind too much length is always better than too little III3 d Draw lead lines for drilling on the side plates 13 Press the side plates on the mast with clamps please protect the plates with convenient means Drill at 5 mm and machine holes so that the conical heads of the pop rivets 14 will be flush with the surface of the side plates There should have at least 12 pop rivets 14 on each side plate 13 III 3 e Fit the Nylon washer 29a onto the vertical gooseneck pin Temporarily fit the gooseneck articulation 10 onto the gooseneck 12 as well as Nylon 29 and stainless steel 30 washers and tighten the low aspect nut 31 and Nylock 30a 4 ASSEMBLING THE LUFF PROFILES Fitting at this stage will be easier flat on the g
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