Made Engineered Romar Leisure Furl furling boom User manual

Owners manual Romar Leisure Furl Rev 0 © Made Engineered BV 2021
Component packing list
OWNER’S MANUAL
Romar Leisure Furl furling boom
The information contained in this handbook is to be
used as a guide for the safe installation, operation and
maintenance of the Leisure furl system.

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Made Type S | in-boom furling system with manual drive
Owners manual Romar Leisure Furl Rev 0 © Made Engineered BV 2021
Contents
1. Components packing list .................................................................................................................. 2
2. Installation.........................................................................................................................................5
2.1 Preparing the mast ....................................................................................................................5
2.2 Fitting the Leisure furl sail track ................................................................................................6
2.3 Fitting the mast components.................................................................................................... 8
2.4 Fitting the boom and mandrel ................................................................................................... 8
2.5 Deck lay-out ............................................................................................................................. 9
2.6 Sail fitting instructions ............................................................................................................ 10
2.7 Checklist after installation ........................................................................................................11
3. Operation ........................................................................................................................................ 12
3.1 Setting up boom height............................................................................................................ 12
3.2 Hoisting the sail....................................................................................................................... 13
3.3 Furling the sail ......................................................................................................................... 13
3.4 Controlling the sail................................................................................................................... 14
3.5 Sail adjustments ...................................................................................................................... 16
3.6 Operating tips.......................................................................................................................... 17
3.7 Trouble shooting...................................................................................................................... 18
4. Maintenance................................................................................................................................... 20
5. FAQ.................................................................................................................................................. 21
6. Glossary of terms.............................................................................................................................23
7. Contact details ............................................................................................................................... 24
8. Disclaimer .......................................................................................................................................25

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Made Type S | in-boom furling system with manual drive
Owners manual Romar Leisure Furl Rev 0 © Made Engineered BV 2021
1. Components packing list
Boom shell
Aluminum or Composite
Mandrel
Aluminum or Composite
Mast track system
Leisure furl track or head car supportable track
Drive system
Manual operation with Dyneema line
Back-up
Back-up recess for winch handle
Sheeting system
Reinforced pad-eyes or tailored solution
Boom vang bracket
Reinforced bracket to match pin and jaw
Support bracket
Internal structure to retain the mandrel
Sail cover
Integrated and retractable sail cover
Topping lift bracket
Stainless steel mounting bracket
LED light
Option
Boom vang
Option

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Made Type S | in-boom furling system with manual drive
Owners manual Romar Leisure Furl Rev 0 © Made Engineered BV 2021
1.
Furling line
2.
Spool and drum for manual operation with locker and back-up recess
3.
Universal coupling connected to spool with through-mast shaft
4.
Aluminium or carbon fibre furling mandrel
5.
Gooseneck bracket with vertical pin and washers (option)
6.
Gooseneck toggle with horizontal pin and washers
7.
Sail cover retraction line
8.
Retraction line clamp (apply by default)
9.
Reinforced boom vang lug
1
2
3
4
6
7
8
9
5

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Made Type S | in-boom furling system with manual drive
Owners manual Romar Leisure Furl Rev 0 © Made Engineered BV 2021
10.
Leisure furl luff track or head car supportable luff track
11.
Flexible feeder and pre-feeder
12.
Aluminium or carbon fibre boom shell
13.
Support bracket with rollers and sail cover guides
14.
Integrated retractable sail cover
15.
Topping lift bracket
16.
LED light (option)
17.
Pad-eye(s) for sheet and preventer
10
11
13
14
15
16
17
12

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Made Type S | in-boom furling system with manual drive
Owners manual Romar Leisure Furl Rev 0 © Made Engineered BV 2021
2. Installation
There are 7 stages to fitting the leisure furl system:
1. Preparing the mast
2. Fitting the sail track
3. Fitting the mast components
4. Fitting the boom and mandrel
5. Deck lay-out
6. Fitting the sail
7. Checklist after installation
Important
▪It is recommended to unstep the mast and position it horizontally (face down) during step 1-3.
▪The area on the aft side of the mast should be clear from obstructions or sharp edges.
▪Before removing or installing any component, check this manual for instructions.
▪The boom should not be raised or lowered more than 10° to its default angle of 90° to the mast.
▪The sail cover retraction line should always be clamped, so it cannot get caught by the sail when furling.
2.1 Preparing the mast
Before any parts are mounted to the mast, first mark the P-measures on the mast. “P” refers to the luff
length of the mainsail.
At the top of the mast, just below the topping lift sheave, mark “TOP P”. Consider the angle the topping lift
will exit at so the topper will clear as the boom articulates. Mark “bottom P” on the mast by measuring the
luff length from “top P”. This mark specifies the sail foot position as well as the top of the furling mandrel.
From “bottom P” set marks at the following positions:
▪X: the distance between “bottom P” and start of luff track
▪Y: distance between “bottom P” and centre of mandrel
▪Z: distance between “bottom P” and the underside of the upper gooseneck lip.

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Made Type S | in-boom furling system with manual drive
Owners manual Romar Leisure Furl Rev 0 © Made Engineered BV 2021
The exact values for X, Y and Z will be provided on a custom drawing. Ask for this drawing if you have not
received it.
2.2 Fitting the Leisure furl sail track
Position the track on the mast. Use masking tape to secure the track to the mast. Drill on both sides of the
track using a 5 mm drill and fit a Monel rivet to each hole before you drill the next. This way the track will not
move against the mast, misaligning the holes. Ensure the track ends are free from sharp edges and line up
X
Z
Y

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Made Type S | in-boom furling system with manual drive
Owners manual Romar Leisure Furl Rev 0 © Made Engineered BV 2021
neatly. Luff tape damage could result if misaligned. Drill each track end using 4 rivets on each side at 20
mm centres from the bottom and top edge. Clean all the holes on the mast and radius the edges.
The bottom section of sail track will need cutting to length at the position where the track finishes (mark X).
Once cut to the finished length, deburr the track end and radius the sides carefully. Luff tape damage could
result if the track end is not deburred and the luff groove is not rounded off.
It is essential that the feeder be correctly positioned at all times, so as to ensure the load of the sail is taken
on the feeder, not the sail track. Incorrect alignment may reduce the life of the luff tape, and risks the sail
not entering the sail track correctly.

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Made Type S | in-boom furling system with manual drive
Owners manual Romar Leisure Furl Rev 0 © Made Engineered BV 2021
2.3 Fitting the mast components
The centre of the shaft that goes through the mast must align with the centre of the mandrel (mark Y). Drill
a hole through the aft side of the mast at mark Y. The diameter of the hole should be slightly larger than the
diameter of the shaft. Deburr the hole on the inside and outside of the mast such that there are no sharp
edges. Drill another hole on the front side of the mast at mark Y in a similar way. The holes must line up
horizontally (90 degree angle to the mast). Again, deburr the hole on the inside and outside of the mast.
Align the aft bearing with the hole on the aft side of the mast and drill and tap according to pattern. It is
advisable to drill, tap and fix the top and bottom hole before you drill, tap and fix the other holes to make
sure everything aligns perfectly. In a similar way, install the drum in front of the mast. Use Tef-Gel to protect
the aluminium mast against the stainless steel bolts.
Position or reposition the gooseneck bracket according to the instructions (mark Z).
2.4 Fitting the boom and mandrel
With the mandrel positioned inside the boom shell and end-bearing, lift the boom into position on the boat.
Preferably, use a crane. Alternatively, use the halyard to lift the front of the boom and use the topper to lift
the aft of the boom, and manoeuvre the front of the boom by hand or with a secured control line to the mast.

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Made Type S | in-boom furling system with manual drive
Owners manual Romar Leisure Furl Rev 0 © Made Engineered BV 2021
Attach the boom to the gooseneck bracket using the vertical pin. Make sure all washers are in place to avoid
clearance.
It is important to keep the vertical angle between the boom and mast approximately 90 degrees during and
after the installation. This is because the boom and mandrel are installed on the mast independently. So the
mandrel will slide inward when the boom is lowered and outward when the boom is raised. The vertical angle
between the boom and mast must always stay within the range of 80°-100°.
When the boom is mounted, it is advisable first to mount and fix the boom vang in order to unload the topper.
After that, the mandrel can be mounted to the mast.
Slide the universal coupling (with mandrel) onto the
drive shaft until the coupling touches the aft bearing.
The drive shaft should not protrude further than the
opening in the coupling. If the shaft is too long, it will
jam the universal in operation and cause the system
to seize.
To mount the drive shaft to the coupling, fit the pin
through the coupling and shaft. Lock the pin with grub
screws and Loctite.
2.5 Deck lay-out
Consider the lay-out for leading the halyard and furling line aft. The rope guide should lead the furling line
off the spool parallel to the mast from the spool center.
block positioned in line with spool centre athwart ships
topping lift / halyard
organizer
cleat to act as a snub for halyard whilst furling
winch
rope jammers
Furling line
universal coupling
shaft
pin