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