CDI FLEXIBLE FURLER 2 Manual

FLEXIBLEFURLER2
INSTALLATION/OPERATINGINSTRUCTIONS
277BakerAvenue / PO Box 1250, Concord, MA01742
Tel: [phone] Fax: [phone]
Web: www.sailcdi.com
November 2001

WARNINGS
Improper installation of the Flexible Furler or improper
reinstallation of the forestay can cause failure of the forestay,
and could result in the loss of the mast and injury to crew
members.
Before installation, check that toggles are used at both ends
of the forestay. Improper toggling may cause the forestay to
fatigue due to bending stresses.
After installation, check that all clevis pins and cotter pins
removed during installation are replaced. specially check that
all turnbuckle pins are in place. Make sure the turnbuckle
threads have full engagement. Check for free rotation of the
unit, paying particular attention that the luff or the inside of the
drum does not touch the turnbuckle body. If it touches, furling
may unscrew the turnbuckle. Insure that the bearing is not
jammed, as winching with a jammed bearing will transmit
torsional loads to the turnbuckle which could lead to failure.
Check to insure that at least 3" clearance exists to the side and
above the halyard top fitting.
During operation, never winch the unit without checking for jams
or snarls. Winching against an obstruction can sever or cause
hidden damage to your forestay. Keep your unused halyards
flipped to the after side of your spreaders. If the unit becomes
hard to furl, investigate and correct the cause. Failure to do so
can lead to the failure of the forestay.
The Flexible Furler is NOT designed to be used while your
boat is in the water and passing under low clearance
obstructions (bridges, power lines, etc) with mast is tipped
forward and headstay attached to the bow. Lowering the mast
in this manner is dangerous even without a furler, and can be
further complicated by the weight of the furler and the sail.

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INDEX
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Uncoiling and Straightening the Luff . . . . . . . . . . . . . . . . . . . . 4 - 5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8
The Furling Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hoisting the Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lowering the Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Sailing with Your Furler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Trailering Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sailmaker's/Rigger's Instructions . . . . . . . . . . . Inside Back Cover
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
SPECIFICATIONS
Forestay Length 29 feet, maximum
Wire Size 1/8", 5/32", 3/16"
Forestay Fittings There should be a toggle at both ends of the
forestay (see second paragraph under
Warnings above). The turnbuckle should be
a 1/4"
or 5/16" swage-on turnbuckle with
T-bolt and toggle at bottom (see, page 5).
Mounting System can not be mounted above
turnbuckle. If you wish to raise system for
better clearance, shorten stay and use
linkplates below the turnbuckle.
Furling Line 5/32" or 3/16" dacron. If you prefer a larger
diameter, you can de-core larger double
braid line forward of the cockpit, thereby
reducing the diameter as it winds on the
drum.

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(3)
PARTS LIST
ALuff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LFF2
BSpool Assembly . . . . . . . . . . . . . . . . . . . . . . . 2010
CLuff Support Pin (3/16" x 1-1/2") . . . . . . . . . . 2009
DHalyard Anchor Pin . . . . . . . . . . . . . . . . . . . . 1998
Halyard Anchor Shackle . . . . . . . . . . . . . . . . 2007
EMain Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 1033
FCup (Stainless Steel) . . . . . . . . . . . . . . . . . . . 1807
GAntirotation Strap . . . . . . . . . . . . . . . . . . . . . . 1081
HFerrule (part of halyard) . . . . . . . . . . . . . . . . . - - - -
JHalyard Top Fitting . . . . . . . . . . . . . . . . . . . . . 2011
KHalyard Assembly (1/4" x 33') . . . . . . . . . . . . 1932
LTack Tension Line (1/8" x 4') . . . . . . . . . . . . . 2048
MThrust Washer . . . . . . . . . . . . . . . . . . . . . . . . 1253
NTack Tension Pin . . . . . . . . . . . . . . . . . . . . . . 1998
TackTension Shackle . . . . . . . . . . . . . . . . . . 2007
Not Shown Instruction Manual . . . . . . . . . . . . . . . . . . . . . 1049

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UNCOILING AND STRAIGHTENING THE LUFF –
PLEASE READ CAREFULLY!
If you received the luff coiled, BE CAREFUL while cutting the tape
that holds the luff coiled. THE LUFF CAN UNCOIL WITH
CONSIDERABLE FORCEAND CAUSE INJURY.
Start removing the tape by cutting the band retaining the outside
end of the coil while holding the straight portion. Gently uncoil to
the next band of tape. Repeat this process until all tape has been
removed. When cutting the last piece of tape, the coil will have a
tendency to spring outwards so be cautious. Never cut the tape
restraining the inner end first as the coil will spring open when the
last tape is cut.
When the tape is removed, the luff will still be curved. To
straighten, you will need three people. NEVER try to straighten by
laying luff on the ground and weighting it down along its length. IT
WILL TAKE AYEAR! Rather, with one person at each end and the
others spaced along the luff, recoil the curved portion in one large
loop in the opposite direction. Note that the lower end from the
sail feed slot to the bottom was shipped straight and should not be
recoiled (see drawing above left).

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After coiling in the opposite direction, tape the upper end to the
lower portion above the sail feed slot (see drawing previous page,
right) leaving the straight portion free. Leave the coil re-coiled for
several hours, a minimum of three if it’s warm, longer if it’s cold.
After this time, carefully cut the tape and check the straightness.
The luff does not need to be perfectly straight as a tight forestay
will finish the job.
Clean the luff with a rag soaked in paint thinner. For deep
scratches and ground in dirt, rub with a rag soaked in acetone. Be
cautious, however, as prolonged exposure to acetone will destroy
the luff.
ASSEMBLY
Assembly is easiest with the mast down although it can be done
with the mast up (see instructions below).
Assembly of Luff Extrusion, Halyard Top Fitting and Halyard
1. Measure the pin to pin length (L below) of the forestay with the
turnbuckle in its normal state of adjustment. If the mast is up, you
will have to raise a tape on the jib halyard and add an amount
approximately equal to the distance from the top end of the tape to
the pin at the top of the forestay. Cut off the top end of the luff so
that the total luff length is 12 1/4” less than the measured pin to
pin length.

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2. The Flexible Furler uses a built-in 1/4” rope halyard instead of
your boats halyard. One end of the halyard has had the rope core
removed leaving only the outer braid while the other end has both
core and braid intact. The de-cored end is closest to the metal
ferrule. To install, insert the intact end into the cavity in the halyard
top fitting and through the off-center curved hole until the halyard
exits from the “nose” on the halyard top fitting. Pull the halyard
through until the ferrule is about a foot from the halyard top fitting.
3. Pass the decored section of the line through the top of the
groove in the luff extrusion opposite the groove with the sail feed
slot (see photos below). Push the ferrule an inch down into
groove. You should now be able to pull on the decored section of
the halyard and have the ferrule slide inside the groove. Don’t do
this until you’re ready to raise the sail. Fit the halyard top fitting
over the top of the luff with the halyard exiting the side of the
halyard top fitting over the groove with the sail feed slot. Tighten
locking screw. Tie a messenger line, the length of the luff, to the
decored end of the halyard. This line will be used to raise the sail.
4. Completely unscrew the swage-end of the turnbuckle and
T-bolt and toggle from the turn buckle body (see page 5 for
terminology).
5. Pass the swage-end and wire down through the halyard top
fitting/luff extrusion assembly. If the mast is stepped, first pass a
light line through the center hole of halyard top fitting/luff assembly
for the full length of the luff. Make the upper end of that line fast to
the cotter pin hole in the swage-end of the turnbuckle using a
piece of wire to make the link. Pull on the light line while pushing
the luff up the forestay. When the swage-end and wire appear,
screw on the turnbuckle body to prevent the luff from sliding down.

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Assembling the Cup, Bearing and Antirotation Strap
6. If your forestay turnbuckle screw is 5/16” in diameter, drill out
the center hole of the bearing with a 21/64” drill.
7. Place the antirotation strap between the two sides of the
toggle.Add enough 5/16” spacer washers on the T-bolt so when
the antirotation strap is up against the bottom of the T-bolt or cross
bar, the washers are just under the top of the antirotation strap
(see photo at left below). Push the T-bolt through the center hole in
the cup and the bearing (see photo at right below). Screw in the
two pan head screws through the antirotation strap, cup and into
the bearing. Refer to page 9, ‘Bringing the Furling Line Aft” to
select the correct pair of holes.
8. Slide the spool over the turnbuckle body and luff. Insure thrust
washer (part M, a 1 3/4” flat stainless washer) is in place inside
the bearing cavity. Screw the T-bolt into the turnbuckle body until
the overall forestay length is correct. Replace both cotter pins.
Note: final adjustment of the turnbuckle can be done after the
installation is complete (see below).
Final Assembly
9. Step the mast (if unstepped), attach the forestay to the
chainplate. Tension rig using backstay turnbuckle or upper shrouds
(if there is no backstay).
T-bolt/toggle with spacer washers
and antirotation strap in place Assembling cup, bearing and antirotation strap

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10. Slide the spool body down the luff, into the cup and over the
main bearing, insuring thrust washer is in place. Lift the luff up off
the turnbuckle body, insert the luff support pin through the hole in
the spool throat. The luff rests on top of this pin.
CAUTION: the luff
must not sit on the turnbuckle body as turning the furler might
unscrew the turnbuckle causing dismasting.
11. Pass the furling line through the opening in the side of the
cup, then up through the hole in the top of the spool flange. Tie an
overhand knot to prevent it from escaping. Before raising jib, rotate
the furler so there are about 20 turns of furling line on the spool.
This will be finished off later.
12. If your jib is full or almost full hoist
(dimension A in drawing at right is less than
12” when sail is in desired position), pull the
halyard ferrule hard up against the halyard
top fitting and cut the halyard so that when
it is tied to the sail, the head of the sail is
just below the sail feed slot. Melt end of
rope to prevent fraying.
If dimension A is more than 12” when jib
is hoisted to desired position, pull the
halyard ferrule up against the halyard
top fitting and tie the halyard to the
sail so the head of the sail is below
the sail feed slot by an amount
approximately equal to dimension A.
When the sail is raised, there must
enough decored halyard to reach
and be made fast to the halyard
anchor shackle. This may take some
experimentation so cut the halyard
only after you confirm the length.
13. If the forestay length needs to be adjusted, remove the luff
support pin, slide up the spool to expose turnbuckle and make
your adjustment. In so doing, you may knock out the thrust washer.
After adjusting the turnbuckle, be sure thrust washer is in place.