Forespar Leisure Furl OFFSHORE IN-BOOM FURLING SYSTEM User manual

1
OFFSHORE
IN-BOOM FURLING SYSTEM
Installation Manual
September 26, 2014

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TABLE OF CONTENTS
Page
Number
3. Disclaimer
4. Componentspackinglist
5. Toolingrequired
6. Gooseneckdrawingdetail
7. Preinstallationinstructions
8. Installation–sailtrack
9. Locationoflufftracktopcap
10. Installation–flexiblesailfeederlimitline assembly
11. Installation–drivecomponents
12. Installation–drivecomponents
13. Installation- Boomand Mandrel
14. Installation– Boom andMandreland Deck Layout
15. Decklayout
16. Sailfitting instructions
17. Mainsheetand vang bail fitting
18. Installation–checklist
19. Globalagent listing
20. IMPORTANT TOPPING LIFT INFORMATION TO INSTALLERS & OWNERS
21. YourNotes
22. IMPORTANT INFORMATION TO INSTALLERS & OWNERS
FORESPAR PRODUCTS CORP.
22322GILBERTO
RANCHOSANTAMARGARITA,CA92688
PHONE[phone] FAX [phone]
[e-mail]

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03.12.09
IMPORTANT Read this first
Installation should only be undertaken by an experienced rigger. Use safety equipment and install during
suitable conditions.
Follow the instructions in this manual. Each Leisure Furl system is custom manufactured to the unique
specifications of this vessel.
If you do not understand a point in this manual, do not guess, request advice.
We have made every effort to explain the installation process as completely as possible. Nonetheless, it is not
possible to anticipate, or address every conceivable problem that might arise during installation. Hence, we
can not accept responsibility for errors or omissions in this manual. These installation guidelines are in-
tended to provide general guidance to an experienced rigger. For specific guidance and technical support,
contact the person who sold you the Leisure furl system. Specific guidance and technical support are funda-
mental to the installation process.
An experienced rigger should have a thorough knowledge and understanding of general rigging installation
principles.These guidelines should be read in conjunction with such other principles.
Such principles shall be deemed to supplement these guidelines.
Installation of 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 loose and should be positioned during the installation process.
This allows for the most precise location of these fittings.
IT IS VERYIMPORTANT THAT THE SAILCOVER BE PULLED TO THE TOP
OFTHE BOOM PRIORTO FASTENINGTHE VANGLUGANDSHEET BAILS.
THISWILLPREVENT DAMAGINGTHE SAILCOVER DURING THEDRILL-
ING & TAPPING PROCESS.
Line controlled vangs like the Forespar®Yacht RodTM should be setup to raise the boom above the 87oangle
when the line is released.
Boom vangs & topping lifts
In-boomfurlingsystems require both a rigidboomvang and a traditional boom toppinglift for safety
and ease of sail trimming.
When furling or reefing, the boom should be adjusted to the required 87oangle and held at that
angle with the support of the boom vang during the furling process. In heavy weather the boom
topping lift should be used to arrest the motion of the boom during furling.
When the boat is moored a boom topping lift will extend the life of your boom vang, no matter what
type; spring, pneumatic, hydraulic or electric.

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COMPONENTS PACKING LIST
1. Luff track top cap
2. Sail track & Base Extrusion 20. Screws – Inner bearing )
3. Flexible feeder 21. Screws – Feeder )
4. Furling mandrel 22. Sail Track aligning plugs )
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
64
85
10
9
13
11
12

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03.12.09
TOOLING REQUIRED
Pencil
Paper
Hacksaw,including spareblade
Scraper
Softhammer
Allenkey set
Hole saw, See Diagram 1 for size
Electricdrill ½” chuck
Electricgrinder 4”
Masking tape
Tappingdrill sizes – 9/64”, 3/16”, 1/4” 5/16”
Drillssizes- 3/16”, 1/4”, 5/16”, 3/8”
Intermediatetaps – 3/16”, 1/4”, 5/16”, 3/8”
Tapwrench
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

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SET UP DIAGRAM
System Shaft size Shaft hole Clearance at Mandrel Datum below Start of base Flexible
size offset to aft end of size bottom of P extrusion feeder
starboard mandrel above length
datum
14/5 L 1 ” 1/4” 1-7/8” 3-1/2” 1-3/4” 32” 18”
14/5 M 1” 1/4” 1-7/8” 4” 2” 32” 18”
18/6L 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 the top of mandrel
Base Extrusion
Above Datum

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03.12.09
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.
If the track is fitted while the mast is in place,
it may require two persons, one to assist
while the other fits the track in place. While
the track is being fitted in position the other
person can be preparing the mast for later work.
For purposes of fitting the sail track, the aft face
of the mast from the bottom of the luff extrusion
to near the deck should be clear from obstructions,
or sharp edges.Any winches, which are inside of
this area,may need to be repositioned.
Hold the castings in their approximate position to
establish if repositioning of any fittings is required.
Consider the side of the boom as it articulates
from side to side. If the mast has a spinnaker
track down its front face, this will need to be cut
short, above the spool position and a fixed ring
fitted below the spool if later required.
(See Diagram 2) Diagram 2
For installation to an existing 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
ofaretrofit,thebottom of P will rise up around 6 to 8”. This will mean a small amountof sail
areawill be lost but theareacan usually be trimmed offthetop of the sail sothe loss will be
minimal. A second consideration is the boom height in the cockpit. Tack angles on con-
ventional sails are normally around 88 deg. and considering that the tack angle is now 87
deg.thiswillalsomeanthattheboom may be higher anyway. Thirdly, consideration has to
be given to the backstay if clearance is getting marginal. While this should have been
considered at the start, if the boom ends up higher at the gooseneck end and on a greater
angle upwards it could start to become a problem.
Note : With a solid vang, check to ensure the stroke is enough to allow repositioning, if the
boom is to be lowered or raised from the current position. Moving the vang lug along the
boom may not always be a good option, as the angles may become unrealistic.
Diagram 2 shows a mast section and fittings
before conversion to Leisure Furl. When the
new inner bearing casting is held at the old
gooseneck height, the lower arrow indicates
where the shaft hole would end up. The bottom
of ‘P’ would rise up aprox. 7”. The spinnaker
track will need to be cut and removed at the top
arrow.
NOTE: The Leisure Furl gooseneck
lugs may be positioned lower than
the original.
.

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03.12.09
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.
INSTALLATION INSTRUCTIONS – fitting the sail track, track slugs
1. After confirming the gooseneck position make a reference mark for the position
datum which is the center of the drive shaft.
Note : The datum position is the reference for all measurements.
2. See Diagram 1, mark a position above datum where the base extrusion will finish.
Refer to Diagram 3a and mark the location of the top of the base extrusion. The top
piece of base extrusion is to be the “cut length” so the base assembly spans the
distance between the top and bottom reference marks. There must be .020 gap
(thickness of two business cards) between each length of base extrusion.
3. Luff track and track base must be installed before any other fittings are
attached to the aft face of the mast.
4. Insert 18 or more 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 ¼-20 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 each hole in
the base.
7. When the first set of slugs are installed, send the first base section to the person at
the masthead for tightening in place while the second track base is being prepared
below. Positionthisfirst“cutlength” section of base extrusion at the reference mark
based on diagram 3a for the location in relation to the main halyard sheave.
8. Alternately, if you are working alone, once you have raised this first section to the
top of the mast and fixed it in place, you can install successive sections pushing
them up the mast as you progress. The base weighs .49 lbs./ft., or 25 lbs./50 ft.
9. Introduce more slugs into the mast luff slot as needed. Progressively add track
base sections and tighten the screws. Ensure that there is a .020 gap (thickness of
two business cards) between all of these sections and make sure each joint is well
aligned. The bottom of the last base extrusion has holes drilled and tapped for
securing the flex feeder piece.

9
Diagram 3a
10. 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” [203mm]
18/6 10.5” [267mm]
19/6 11.5” [292mm]
20/7 12.0” [305mm]
25/8 14.0” [356mm]
11. Models 14/5, 18/6, 19/6, 20/7 & 25/8 & 25/8 OS use a two piece base and foil
system. The foil 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” between the foil sections is established by the use
of the retainer clips.
LUFF TRACK ASSEMBLY
FOR 14/5, 18/6, 19/6,
20/7, 25/8 & 25/8 OS
MODELS
ALUMINUM
LUFF FOIL
ALUMINUM
BASE EXTRUSION
STAINLESS STEEL
RETAINER CLIP
Diagram 3b

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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 jointsandlufffoiljoints allow for modest mast bend
withoutcrushingtheendsoftheextrusions.
INSTALLING THE 30” POLYMER FLEX FEEDER
Anyburrs or sharp edges on the ends ofthefoilswillcause luff tape friction, wear and
failure. Thisis why theonly“field-cut” length offoilis at theverytop of theluff foilassembly
wherethe sail neverreaches. Inspect all lufffoilends during installationandsmooth as
necessaryusingfinegrit 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
isslidontothebaseextrusionandsecuredusingthetwo10-24X 1/2” fillister head ma-
chinescrews. Drillusing 9/64” bit. Carefully use the flex feeder as a drill guide to locate
thefastener locationsonthe base extrusion. DONOTdrill thebaseextrusion through the
flexfeeder. Thisactioncould result in the holesintheflex feeder being elongated. Itis the
shearstrength of these screws thatholdsthe flex feeder in place. ApplyLocTiteandtighten
themmaking sure their heads are belowtheinsidesurface of the flex feeder.

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INSTALLATION INSTRUCTIONS – Flexible feeder limit line fitting instructions
Thelimit line assembly consists of two stainless steelterminationblocks and a fixed length
of SpectraTM 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. The limit line should be loose
enough to allow the track to flex port and starboardbut not aft. With that in mind, the
termination blocks should be installed on the mast sides as shown in the diagrams 4 & 5.
The termination blocks are installed using the 1/4-20 FHMS provided, use an F or 3/16”
drill. The knot in each end of the limit line must be pushed out of the termination block to
expose the fastener hole. This will allow marking of the mast for drilling and tapping, as
well as installing and tightening the screw. This may require flexing 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
onthe luff of the sail. Ensure that the87oboomangle is correct, then watch as sail therolls
into the boom. Furling should be checked at different angles to the wind, since this is the
true test of the flexible feeder setup.
Once the termination blocks have been
installed on the mast, the only way
to affect the amount of flex in the
unsupported portion of the luff track
is to change the length of the limit line.
If less flex is deemed necessary the
line can be shortened.
If a longer line is required for
additional flex, SpectraTM
line can be purchased
from your local chandlery.
Use a figure eight stopper
knot in each end then trim
the ends as necessary. Diagram 4
SIDE VIEW
Diagram 5
BOTTOM VIEW
TERMINATION BLOCK
LIMITLINE
FLEXIBLE FEEDER
S/S LUFF FEEDER
TRACK BASE

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03.12.09
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
the datum position and draw neatly around to form
a parallel edge at the datum position.
Mark the aft center position on datum line and then measure
evenly around both ways to find the center forward position
on the front face of the mast. Next mark the indicated distance
to Starboard (See Diagram 1) both on the forward and aft face.
Use center punch to locate center of drive shaft hole.
Remove the straight edge and put aside to use as a packing
gauge when drilling the universal shaft pin hole. Using the
correctly sized hole saw, based on shaft diameter, drill the
first drive shaft hole at the 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 of
the two side plates. If either side plate touches the mast wall
before the center, grind the affected area until the spool fits
neatly in position. Thin washers can be used if necessary to
ensure spool touches on the center.
Once fitting closely, the Spool and Inner Bearing castings can
be temporarily fitted against the mast,
Once the spool cover and inner bearing castings fit properly,
Prepare the mast for the seating compound. The seating
compound is used to fill any voids between the castings
and the mast. It also acts as a corrosion barrier between
the mast and the stainless inner casting.
With the inner bearing and the spool cover off, place masking tape on the mast in the
area where the castings will sit. Be sure to mask outside the casting an inch or two
Diagram 6
Diagram 7

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03.12.09
Placethe inner bearing and spool back in their proper position onthemast. Marktheouter
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. (See diagram #7)
The seating compound will require a sound base on the mast to adhere to, so sand the
area, then clean with a solvent to remove any oils. Mask around the edges of the castings
also,and grease the Spool shaft as compound may dry on this, making it difficult toremove
after fitting.
Mix the seating compound with hardener at approximately 2% by weight (use less in hot
weather) by volume. Mix this well until the hardener is blended with the compound. Place
equal amounts of the seating compound around the castings then position in place on the
mast.Workingtimeof the seating compound will varydependingonthe temperature. Take
caution in hot weather as the compound can go off within a minute. In cold weather it can
take 10-15 minutes or longer.
Assemblethe castings and drive shaft in place on the mast. Use the plastic spacer strips or
the cardboard template to centralize the spool plate around the cover. Push both the inner
casting and spool cover really firmly against the mast. Install the clamping tube assembly
over the drive shaft (with the clamping tube against the inner bearing). Be sure to grease
all components that will come in contact with the seating compound or some parts may
become stuck. Tighten 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
thathas spilled out to fill but if the weather is hot,bequickasyoumay 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 compound dries. Do not attempt to wipe the excess away.
Allow the compound to tack off then cut around the castings with a sharp blade, to remove
excesscompoundbeforeitfullycures.Donotleaveittoolongbeforecuttingtheexcessaway
as when it goes properly hard if will be a big job to clean it up.
Afterthe compoundhascured adequately fastenthe Inner bearingbymachine screwing
this to the mast with the screws supplied. Drill and fasten the two center screws first so as
not to misalign the casting. Use LocTite on all inner bearing fasteners. Tighten the
screws in sequence when all fitted to ensure no possibility of pulling.
Insertawinchhandle intothe forwardfaceof theSpool plate,androtategentlyto eitherside,
tofreethedrive shaftandfurling spool.Disassemble theclamping assembly. Leavethetape
securing the spool cover to the mast. Be careful not to disturb the Spool cover as it sits
againstthe mast. Thespoolplate and drive shaftcanbe pulled away fromthemast. Fasten
the Spool cover by machine screwing this to the mast with the screws supplied. Drill and
fastenthe twocenterscrews firstsoas nottomisalign thecastingwith thedriveshaftcenter.
Tighten in sequence. Remove tape. With aroundfileor scraper gently remove any excess
compoundfrom inside the drive shaft hole and bearingarea.

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. This should
not cause a problem unless it is really forcing hard. In this instance the rivets holding the
tube above and below the shaft will need to be removed, reducing tension on the tube. If
possible re-rivet the tube over to one side. No damage will result if the wiring tube rubs
slightly on the shaft.
INSTALLATION INSTRUCTIONS - Fitting the boom and mandrel.
With the furling mandrel positioned inside the boom shell lift the boom into position on the
boat.
Attach the boom to the gooseneck using only the gooseneck vertical pin supplied.
To fit the vertical pin, align the gooseneck spacers and knuckle with the tangs on the mast.
Once fitted in position, fasten the pin in place with the washer and screw supplied.
Check to ensure that the vang and 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 Diagram 8) This is extremely important as the universal will jam in operation
and may cause considerable damage to the components or mast. Diagram 8 shows
end of the shaft (tinted blue) flush with the inside of the universal boss.
The shaft must not extend past flush.
Using the correctly sized drill bit, drill the Universal drive pin hole.
The universal has a machined hole on one side, hidden by an O-ring.
Remove the O-ring and drive pin. Use a business card, or similar
thickness piece spacer between the universal face
and the inner bearing casting face to give a small
amount of clearance, otherwise the whole unit
may end up tight when the pin is installed. Through
one of these holes, drill into the drive shaft approx.
3/16”. Fit the Universal drive pin into the hole to
avoid any misalignment and rotate the mandrel
180 degrees. Drill into the drive shaft the same
depth on the other side.
Diagram 8

15
Lineup sheavewith
center of spool
Adrill 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. If drilling through the shaft with a drill press,
remove the shaft once center drilled. When reset up actually ream the hole with the drill
until the pin is a tap in fit. It 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 leather cover over the universal coupling.
DECK LAYOUT
Consider the layout for leading the halyard and furling line aft. If the existing vang and
topping lift lines terminate at the mast, it would be desirable for these to lead aft also.
Thefollowing diagrams offer suggestions whichhaveworkedwell on previous installations.
Diagram 10Diagram 9

16
03.12.09
On new boat installations there is no need for a rope guide, providing a deck block can be
locatedas per diagrams 9 and 12. However with existing boats,dependingonthesituation
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.
It is essential that the mainsail remains visible during both hoist and furl, so position the
operating switch and control lines in the cockpit in a position to allow this. Use of the
existingropeclutchesmay determinethe positionforoperation.Theoperatingswitch 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 halyard
or position a 6' T cleat for the purpose
Diag. 13
Diag 14
Rope guide
Furling line
Stand up spring turning
block in line with spool
center
Organiser
Rope jamber
Winch
Winch Rope jamber
Furling line
Organiser
or position a 6' T cleat for the purpose
Use another winch to snub main halyard
Rope clutch
Rope clutch

17
Leisure furlLeisure furl
Leisure furlLeisure 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
1. 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.
2. Attach first the tack to the furling mandrel, leaving around 30mm between the tack
web and tack ring on the universal.
3. Now lash the clew to the outhaul saddle on the mandrel. Do not pull the foot out
tight, leave fullness in the foot for efficient down wind sailing. The in built sail controls will
generate outhaul tension – see owners manual page 8, 9, and 10.
4. Lash the clew with a minimum of three wraps around the furling mandrel,
using a separate lashing, pulling the clew down to within 3/8” of the mandrel.
5. Using a winch handle inserted into the 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 this instance the furling
line will need to be pre-wound on the spool before the sail is attached, and the boom set to
the correct angle for furling, (see owners manual for hoisting the sail) before the sail is
hoisted.
7. With the sail rolled on the mandrel, fasten one end of the furling line to the spool, (if
not already in position as a result of note 6 above), by firstly placing five turns around the
spool drum in an anti clock wise direction, looking aft. Then pass the free end through the
hole in the spool. Tie a single knot as close to the end as possible, and push the knot into
the counter bore of the spool drum.
The sail fitting is complete, However minor adjustments may need to be made. See owner
manual for guidance.
A luff lube with a PTFE or similar base should be applied to the luff tape as needed
to reduce the friction in the luff foil.

18
03.12.09
Leisure furlLeisure furl
Leisure furlLeisure 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.
1. Position the bail in the track, mark the location of the first hole then slide the bail out
of the way. Do not attempt to drill the boom through the threaded hole in the bail as
the drill could damage the threads in the bail.
2. Drill the first hole 9/64” (14/5, 18/6 & 19/6 system bail) or 1/4” (20/7 & 25/8 system
bail) hole through the top of the track.
3. Mark the location of the second hole then slide the bail out of the way, and drill the
second hole through the top of the track.
4. Thedrill 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 screw, and tighten. The dog set screws and Loc-Tite must be used at
every threaded fastening point of the bail.
6. When tight, the set screws force the bail tight against the underside of the track.
The dogs lock into the drilled holes which secures the bail against the thrust loads, pre-
venting the bail from sliding in the track.
7. All bail set screws must remain tight. Checking these screws should be a part of
the regular preventative maintenance inspections on your Leisure FurlTM boom.
LOWER CAVITY AREA
TOP OF TRACK DRILLTHESE HOLES
DOG SET
SCREW
DOG
SHEET BAIL

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Leisure furlLeisure furl
Leisure furlLeisure 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. Ensure the outer bearing is lubricated.
3. Ensure the spool spins freely.
4. The end spacing between the universal and the inner bearing needs to be approxi-
mately 1/32” [.8mm] (the thickness of a business card).
5. Ensure all machine screws have been treated with an anti corrosive compound.
6. Ensure the sail track slugs are locked in place and tight in position. If any slugs are
thought to be faulty, rivet the track in this area.
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 leadaft, avoiding friction where possible, andtherope guide is
set correctly for alignment from the deck to the spool See deck layout.
12.Ensure the boom angle to the mast, is not limitedbytheVang orTopping lift adjustment.
If a spring / fixed vang is used, ensure the vang can support the boom weight.
The 87oangle to the mast is important.
13.Ensure the drive shaft does not protrude through the back face of the Universal drive
coupling. (See Diagram 8) Ask if in doubt, this is extremely important.
14.Wash the boat off thoroughly as filings could be caught in deck lines or may rust on the
deck.

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Leisure furlLeisure furl
Leisure furlLeisure furl
Leisure furl Global Service
ASIA
KZ Marine Ltd
39 Vestey Dr, Mt Wellington
Auckland New Zealand
Ph [phone]
Fax [phone]
Email[email protected]
AUSTRALIA
KZ Marine Ltd
39 Vestey Dr, Mt Wellington
Auckland New Zealand
Ph [phone]
Fax [phone]
Email[email protected]
CARIBBEAN
FKG Rigging
Philipsburg, St Maarten
Netherlands Antilles
Ph [phone]
Fax [phone]
Email[email protected]
ENGLAND
Romar b.v.
De Hagen 17, 8325 DB Vollenhove, Holland
Ph [phone]
Fax [phone]
Email [email protected]
EUROPE
Romar b.v.
De Hagen 17, 8325 DB Vollenhove, Holland
Ph [phone]
Fax [phone]
Email [email protected]
FRANCE
Gremco S.A.R.L.
1955 Ch De St-Bernard
06220 Vallauris Cedex
Ph [phone]
Fax [phone]
P.L.M.Yachting
70, rue des Saints Peres
75007 Paris
Ph [phone]
Fax [phone]
Email[email protected]
Leisure furl International PO Box 22800
Otahuhu Auckland New Zealand
www.leisurefurl.co.nz
GERMANY
ReckmannGmbH
SiemensstraBe 37-39
D-25462 Rellingen
Ph [phone]
Fax [phone]
HOLLAND
Romar b.v.
De Hagen 17, 8325 DB Vollenhove, Holland
Ph [phone]
Fax [phone]
Email [email protected]
Proctor Holland b.v.
Middenhavendam 1
4511 AX Breskens
Ph [phone]
Fax [phone]
Email [e-mail]
ITALY
G & G rigging
Via San Giuseppe 15
20099 SESTO SAN GIOVANNI (MI)
Ph [phone]
Fax [phone]
NEW ZEALAND
KZ Marine Ltd
39 Vestey Dr, Mt Wellington
Auckland
Ph [phone]
Fax [phone]
Email [email protected]
SPAIN
Yacht tech
C/Ca’n Valero 40
Poligono Can Valero 07011
Palma de Mallorca
Ph [phone]
Fax [phone]
A+ Rigging Mallorca s.l.
C/ Miguel de Cervantes,
14 Bajos
07181 Costa d’en Blanes
Ph [phone]
Fax [phone]
Email [email protected]
UNITED STATES
Forespar Products Corp.
22322 Gilberto,
Rancho Santa Margarita, CA 92688
Ph [phone]
Fax [phone]
Email [e-mail]
Web Site www.forespar.com